this winter, take your bike to the machine shop, and have them cut the header, remove the cat, and weld it back together correctly. THEN get the fuel curve correctly modded for the loss of restriction. I doubt you will have to mod the airbox like the 1250 guys do to get more air through the intake to make power, because the size of the engine is half that to start with, with the same airbox setup, so don't worry about that. remove the PAIR system, and the related smog equipment before you get the bike tuned. Pull your lefthand fairing, and your righthand frame cowling, jump the upper right pin, and the lower right pin on the white 6pin plug under the righthand cowling to put the bike into "dealer" mode. you'll be able to now set the TPS correctly.
A cheap "Suzuki TRE" plug off of ebay (30-50 bucks or so) will negate the need to cut and splice wires, as long as you don't mind the gear indicator being wrong when you use it. but again, you can literally just pull it off the bike, and it's back to normal instead of wires being mangled.
I imagine swapping in the cams from the 1250 engine, will net a sizeable gain, but no one's yet done this.
THAT, will make more power. In a nutshell. the K&N will net NOTHING for the 650 engine by the way. to airfilter and airbox is basically oversized for the engine, and isn't even close to being a restriction. don't buy one.
Also... if you're already planning on the power commander to correct the fuel curve, ect...
http://cgi.ebay.com/ebaymotors/Suzuki-G ... 038wt_1165That, will fix your exhaust, and has NO provisions for the down draft O2 sensor, but power commander deletes the O2 sensor there anyway.
what a passing of good fortune...
