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Library Home Page > 2nd Generation (1999 to current) > Exhaust
Modifying The Stock Mufflers
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How To Modify the Stock Mufflers

This is a description of what some people have done to their mufflers. No one recommends that you perform the operations described here. If you choose to do so, it is entirely at your own risk and responsibility.

To get a little better sound from your bike, you can either buy aftermarket mufflers or modify your OEM units. The former can be expensive, with a set costing $375 or more while the latter costs nothing, but does require that you irreversibly modify your mufflers.

This modification will give your bike a deeper, more aggressive sound and does not require re-jetting of the carburetors. There is no evidence that it improves performance or has any effect on gas mileage. This procedure can be performed while the mufflers are still on the bike.

Looking into the end of the muffler, you will observe that the central pipe is welded to the cone. The cone is not attached to the outer shell. To remove the cone, use a 1-1/8" diameter hole saw to cut the weld from around the central pipe. To aid in the removal of the cone, it may be necessary to drill some holes that you can pry on to pull it out. The cones won't be replaced. Be careful not to damage the chrome outer shell when drilling or prying.

After the cones are removed, you will see a baffle inside the muffler. Drill 4 or 6 1/4" holes equally spaced around the diameter. Start the bike up and check the sound. If you like what you hear, you're done. The sound can be adjusted by drilling the holes out to 3/8" or even 1/2", but remember, you can't make them smaller once they're drilled.

To make the holes at an equal spacing around the baffle, make a cardboard template that has the hole centers marked. Cut it to fit inside the muffler and make a cutout so that it fits onto the tail pipe. Then use a small drill to make pilot holes using the center marks on the template as a guide. Click here to hear them.

If for some reason you want to return the sound to stock, you can plug the holes with stainless steel buttons that have spring fingers around the diameter to hold it in place.

The photo at right shows a method to adjust the sound of your drilled pipes by closing off the holes with a metal plate installed over the inner tail pipe. The plate is sized to match the pipe and baffle and is secured to the inner tail pipe with a 1-1/4" snap ring. It has holes drilled into it to match the holes in the baffle. To make the mufflers quiet again, rotate the plate to cover the baffle holes.


Last update: 05:26 PM Sunday, September 26, 2004

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