The swedge seems to be about an inch short.  I'm installing it on my 2002 Savage,  There was absolutely no space for the graphite gasket.  I am in contact with Supertrapp.  Dynobob, what year is your Savage?

bikingb wrote on 12/31/69 at 16:00:03:

What does this mean ?

I seem to remember from Bert's German forum that in some cases the head pipe was configured differently by Suzuki in the early years of this century. You can use a hack saw to cut part of the smaller diameter inner pipe off to allow it to go further into the SuperTrapp w/o damaging anything. We did that on my B-i-L's 87 to get the adapter for a HD XL muffler to fit. Also I think it is important to start with a new head to pipe gasket and head pipe to ST if it is used. I can't remember if I used the pipe to muffler one when I ran a ST, it was many exhaust attempts ago. The ST is nice and looks good plus the design of the expanding taper is supposed to help with torque. I just had a chance to do someting different and am pleased with it. Sluggo is supposed to get the ST whenever he comes by.

My bike is a 2002 so the idea of the earlier years and their designs won't exactly work.  The "swedge"  is the area on the ST that expands to fit on to the original head pipe of the bike.  Either it is too short or the headpipe is too long.  From what I gather, it is common practice to cut off the headpipe and inch so that the Supertrapp will fit snug.  That makes me nervous. (Cutting the headpipe.)  

I talked to a customer service guy from ST and he said I should not have to cut it off.  He seemed really surprized that I would be having a problem fitting it.  The ST is significantly lighter than the original muffler (massive understatement).  I have some concerns about quality.  If I cut off the headpipe and attach the ST and then decide I don't like it, then I have to get a new headpipe to the tune of about $200.  

Also, when I talked to one of the service guys at the dealership, his opinion was that the ST was just for looks and sound and didn't influence performance that much.  What do you folks think about that????  I think we have probably covered that.  I have already done the re-jetting 152.5 and 1/2 of the white spacer.  I'm under the impression that I need to change my muffler or go back to the original jetting.  

Wish I could really ride right now to tell the difference.  It is snowy and icy outside.

bikingb wrote on 12/31/69 at 16:00:03:

Yet another person working at a dealership that knows very little about bikes. It makes a HUGE difference in performance.

BTW, I run a 157.5 main jet.

bikingb wrote on 12/31/69 at 16:00:03:

Just wrap a wet towel around it.

If you replaced the bowl screws with stainless allen heads the main jet is very easy to change. You don't even need to take off the tank.

You don't want to go too lean - it's not good for your bike. I wouldn't go any smaller than a 155 with the Supertrapp. My bike works very well with the 157.5. Good performance and good gas mileage.

Edit: spelling

bikingb wrote on 12/31/69 at 16:00:03:

While the main jet meters from 3/4 to full throttle, it does have some affect on the mid range too (where the needle meters).

If you're too lean on the main jet and you twist the throttle at any speed, you could be dangerously lean. This can burn valves and hole your piston top. For a cheap piece that is very easy to change I think it's a no brainer.