Hi guys, first time writer, long time reader on the forum.

I was wondering if anyone here has made any modifications to the stock exhaust on the Savage/S40?
I currently have a screaming eagle replica exhaust on my bike, but I think it looks ridiculously compared to the original exhaust and wonder if someone here has modified the stock exhaust to give better performance and, especially, a nicer sound?

My mother (yeah, skip the jokes) had a Savage a few years ago and it sounded waaay better with the original exhaust. I know that something was modified in it but I never got the chance to find out what.

Mine look totally rivited/welded up, can't see any way to remove the baffle. Is there any difference to the exhaust on my California -06 and my mothers European ~95?

Someone had opened mine before I got it, so I am not 100% sure what they look like inside when stock.  If you want, you can look back a few weeks for my "This muffler is screwed" thread.  There are pictures there.

What I have found on mine is that the back plate is riveted into a ring that is part of the body of the muffler.  Attached to the inside of this plate is a mesh cage full of fiberglass, or asbestos, or whatever.  It looks a little like a silencer for a pistol.  Farther toward the front, maybe a foot or so, is another plate with about a one-inch hole in it.  

So, what has been done to mine is this:

1) The rivets in the back were removed and replaced with lag screws.
2) The weld that holds the cage closed was cut and the fiberglass removed.
3) Three, 5/16 holes were drilled in the forward plate using a bit extension.
4) I just yesterday changed to a larger pilot jet.

Now, more or less depending on my mood, I can remove or replace the back plate for a SIGNIFICANT change in the sound.  When the plate is in, it is still louder than stock, but not too bad.  When it is out, I worry some about upsetting the neighbors, but you should see the deer scatter ahead of me.

That plate fits tightly inside the body of the muffler.  I just run a bar or channel lock handle or whatever is at hand inside and use it as a lever to wiggle it and then pop it out like a cork.

This will definitely change the way the bike runs, so be prepared to make changes at the carburetor.  I won't know until tonight if I have made the right change or not.  Haven't run it much with the new jet in.

Good luck!

Sandy said
"That plate fits tightly inside the body of the muffler.  I just run a bar or channel lock handle or whatever is at hand inside and use it as a lever to wiggle it and then pop it out like a cork."

Wassamatta? Your throttle wont push it out? Fire that thing up & crank it open. Might want to be mindful of whats "Back There", I have no idea how far it might go, but it sounds like it would be fun.

justin_o_guy2 wrote on 06/24/08 at 06:50:36:


You're right.  It did sound like fun.  So I went and tried it as soon as I read what you said.  I just put it in kinda loose, so it was just barely engaging the muffler and opened 'er up.  The plate and cage (baffle?) just kind of pooped out a little and hung there limply.  

You had me hoping for projectiles.  Instead I just got projections.  Rats.

Thanks for all the input guys. I guess I'll tear into the sucker when I
have time to go to the workshop next time.

Ps. The workshop I'm referring to is Techshop. If you have one near you should check it out. They have a lot of cool machinery.   http://www.techshop.ws/

Todd Perry wrote on 06/26/08 at 09:50:31:

when i lived in O town there was a place by the full sail school by ucf..