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General Category >> Rubber Side Down! >> Modifying the stock muffler
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Message started by Brandon on 07/24/08 at 18:02:11

Title: Modifying the stock muffler
Post by Brandon on 07/24/08 at 18:02:11

Hey all! I finally got around to taking my muffler off and having a look. I removed the backplate with a drill and a plasma cutter. ;D (That was fun! :D) I couldn't believe the little tiny tube the exhaust comes through. That was fun! I am currently trying to figure out a way to get out the next plate in there. Has anyone done this before or have an idea as to how to get that one out? I'm also wondering how much I have changed the flow through the muff, if i should rejet yet.

Title: Re: Modifying the stock muffler
Post by Sandy Koocanusa on 07/24/08 at 18:13:08

I don't think you've changed it much yet. That next plate has the same little tiny hole in it. I drilled three holes in my forward plate to begin with. Just today I drilled seven more of them. I'm bound and determined to open that exhaust up and lean things out.

Title: Re: Modifying the stock muffler
Post by Brandon on 07/24/08 at 18:28:20

I started with three 5/8 holes in my backplate too. If you come up with a method of removing/ opening up that next plate let me know and I'll do the same.

Title: Re: Modifying the stock muffler
Post by flcruzr on 07/24/08 at 18:32:15

This is what Bill67 passed on to me about modifying the stock muffler...1/2 in drill bit about 14inch long drill in the hole a the back of muffler you might need and extension to get that long theres a plate in there you drill thought, also another plate about 2inches deeper you can drill thought also makes it louder but not much.

Sandy, has the muffler given you any deeper sounds after just drilling the holes in the back plate?

I too have been thinking of doing something like this.

Title: Re: Modifying the stock muffler
Post by Sandy Koocanusa on 07/24/08 at 18:38:30

I wasn't very clear, there. I removed the back plate and all the packing and junk that was hooked to it. Then I drilled the holes in the front plate using a bit extension and bit.

Yeah, it has a deeper sound. It's much, much louder than stock for sure. But it doesn't sound as nice as the Supertrapp or the Raask that I've listened to in person on others' Savages.

Title: Re: Modifying the stock muffler
Post by flcruzr on 07/24/08 at 18:42:20

Sandy, how far in is the other plate you drilled holes in from the opening of the muffler??? I would like to try this, I dont need it too loud and this might be just as much as I need.

Title: Re: Modifying the stock muffler
Post by Sandy Koocanusa on 07/24/08 at 18:43:22

I'll go run a tape in there and find out. Meanwhile, check your PM inbox. Sent you a message.

Title: Re: Modifying the stock muffler
Post by Sandy Koocanusa on 07/24/08 at 18:45:37

Nine inches from the back of the muffler to the front plate.

Title: Re: Modifying the stock muffler
Post by flcruzr on 07/24/08 at 18:46:56

well, I guess I need to go buy longer drill bits!

Title: Re: Modifying the stock muffler
Post by bill67 on 07/24/08 at 18:51:01

I have drilled out almost every muffler like that all mufflers are different Hondas where a lot louder suzukis don't get as much louder they all sounded better the s40 didn't sound much better at all but is a little louder it gives a little more high end power but loses a little low end torque. My boy drilled his victory like that and it sounds real good but isn't real loud .I really myself don't like a real loud sound.

Title: Re: Modifying the stock muffler
Post by shermeco on 07/24/08 at 18:52:09

A couple of weeks ago I went to the Harley dealership and was given a sportster muffler so to get past the plate i took the sawzaw to the bad to and still couldn't get the canister out that has the packing boy was it fun hacking away with that sawzaw just watch out for the brake cable if you do this good thing my wife was there haha as she yelled " HEY your gonna cut that gray cable thingy is that important?"

Title: Re: Modifying the stock muffler
Post by bill67 on 07/24/08 at 18:53:49

First plate is 11 inches back from back of muffler second plate would be about 13 inches

Title: Re: Modifying the stock muffler
Post by flcruzr on 07/24/08 at 19:07:02

I'm going to give it a try on my S40 and see how it turns out. Afterall, I just want a little deeper sound from it. If I end up not liking it then I will have to purchase an aftermarket muffler. Sandy & Bill, thanks alot for all of your info and advice.

Title: Re: Modifying the stock muffler
Post by flcruzr on 07/24/08 at 19:08:16

49525F48575F59553A0 wrote:

Have you had a chance to install the new muffler and if so, How does it sound?

Title: Re: Modifying the stock muffler
Post by Sandy Koocanusa on 07/24/08 at 19:09:00

Yah shoor youbetcha!

Title: Re: Modifying the stock muffler
Post by bill67 on 07/24/08 at 19:12:34

Its not really going to be much deeper just a little louder,I don't know why all other bikes where deeper sounding.

Title: Re: Modifying the stock muffler
Post by flcruzr on 07/24/08 at 19:45:53

Louder would be good enough. I guess anything will be an improvement over completely stock. :-/

Title: Re: Modifying the stock muffler
Post by FreeSpirit on 07/24/08 at 19:59:19

If you just drill out the stock muffler ,do you have to do any other changes? Like carb,etc.

Title: Re: Modifying the stock muffler
Post by bill67 on 07/24/08 at 20:14:06

Should go up on low and high speed jets.

Title: Re: Modifying the stock muffler
Post by Brandon on 07/24/08 at 20:39:28

I guess I need to find a long drill bit then. (whistles) Now where did that thing go?

Title: Re: Modifying the stock muffler
Post by flcruzr on 07/24/08 at 21:50:53

01160E130A0D170B060D0A1706630 wrote:

What year bike do you have? Could you let us know how you like the sound once your done. Thanks!

Title: Re: Modifying the stock muffler
Post by Brandon on 07/25/08 at 20:59:37

Mine is a 2001 It sounds pretty good now, before I only had three holes in the backplate. It sounded like I had an exhaust leak. My dad said it sounds like a suped up lawnmower. (Dang HD rider!!)I completely removed the backplate and the small tube, and drilled four 1/2" holes in the next plate. Its a good cheap way to make more sound. Sometime I will invest in a actual slip on of some type.