I think ill try out the drill mod first and see how that goes! I wont mind digging into a re-jet but id rather wait to do somehting like that until I make other changes I have in mind such as putting a K&N air filter on and such. Wouldnt want to re-jet for the new muffler only to then re-jet for the filter change. Ive got BIG plans for the bike over the winter.  

Just to let you know, I added the sound clip of the HD muffler with a 1/2" hole in the baffle.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1151331237/3#3

It's normal to have a shutdown poof on these bikes.  It's do to the wasted spark ignition system.  With proper tuning of your carb it will be more of a poof instead of a bang though. Also note that with a more open exhaust your shutdown poof will be louder then the stock non-modified muffler as there is not as much to absorb the sound of it.  The main reason you really didn't hear it before you did the adjustment of the carb and the muffler drilling is because of 2 things, 1 they are set fairly lean from the factory and 2 the stock muffler is very effective at sound reduction to the point that it sounds more like a sewing machine  

At first I felt emberassed about the bang during shutdown then I had a bunch of hard core riders tell me that our bikes have a nick name out this way.  I thought it was funny and now look forward to the poof. I've noticed that if I don't shut it down right away the poof is very minimal. Oh yeah, they call our bikes " The Little Banger "  

Ran, just let the clutch out a wee bit while the bike is in gear and idling when shutting down, and this alone will reduce your pow 90% of the time. Most of the time I dont really care if she pops but sometimes its just annoying . I.e late at night, in a parking garage, etc. Hope that helps.

So I tried letting out the clutch a little bit on shut down and it still let out a mean bang!  :'( ! Maybe I didnt let it out enough? Im going to have to look into a new muffler i suppose!

RanDaMan wrote on 07/09/12 at 06:32:02:


A new muffler won't make the shutdown back-fire go away by itself.  It will backfire if it's running too lean or too rich.  So, it sounds like yours is about right or maybe a little lean on fuel-mix...so changing the muffler to something more free flow than the drilled stock exhaust will make it backfire more (not less) unless you also change to bigger carb jets. (As I understand it...someone correct me if I'm wrong.)  So, I'd wait until you get the muffler you like before you rejet, because you might have to do it again with a different muffler.

Check the thread in the tech section on the carb spacer mod...that eliminates the backfiring for most people, although I can't attest to that personally since I haven't done it.  Mine backfires occasionally on decel (depending on the weather...backfires more when it's really humid, which suggests mine is running a little rich) and sometimes on shutoff...the backfiring on decel can get a little annoying, but I can live with it...I don't care too much if mine backfires on shutoff.  

Cheers,
Dave