I put the quieter reverse cone on beast but I'm still working thru some issues.

joeyt wrote on 02/05/19 at 15:04:53:



 
Did you look under "Motorcycle Exhaust Builder Components" on their site ?

REX has a Test Unit muffler that was part of Cone Engineering R&D program about 14 +/- years ago.  It started life as a large bologna shaped & chromed muffler for the big HD road bikes.  I did change it slightly by completely removing the outer shell, and I've just used the inside which is the actual muffler.  Besides I just REALLY like its shape.      It does have a straight through core of 1.75", with dual coil passageways around the core.  Those passageways are made in slightly different size/shape.  The muffler works well in low-mid range with a nice low rumble which builds in the upper range.  It does aide, noticeably, in the prevention of the backfiring of the engine if/when jetting/tuning may not be perfect in some part of the range.  

I did have a '09 S40 that I put both the chromed trumpet style and the quite core muffler on the bike.  I liked them both.  The trumpet looked very good and sounded great but it was loud.  The quiet muffler looked good in the brushed SS, the welds perfect, good strong steel, and it had a nice low rumble when idling and it increased gently as you reached the high range.  It was never what I think of as loud, just a nice rumble all the way.

Solid advice you two. Thank you.

So with the jet kit on the way, and probably a cone muffler coming after that, I'm going to call up my buddy and see if he still wants to do a header for me.   Overall excited.

I'll ask him! 1.5" header. Im undecided yet if I'd like to ask him to copy the original header, or something more similar to the Ryca one. He can be a bigger grump than I.  

Edit 2/8
A quieter cone is on the way, 1.5". My buddy got busy, and is unavailable to whip up a header. Can't blame him with his situation.
Any muffler shop should be able to weld one up, correct? Is there an off the shelf flange anybody knows of that I might be able to take to them or would they be able to copy the one on the bike?

It's hard to find a place in LA that will do the job these days.

I haven't read this entire thread so possibly someone has already brought this up but your problems sound like a stock fuel petcock failing.  Most people eventually switch to a Raptor petcock.  In the tech section there is a thread that explains how to replace it.

If the stock petcock was failing, it may have been weeping (on) without the engine vacuum, check your oil level to see if it has gone up, smell your oil also if it smells like gas. Change it if so, even a little bit of gas in oil is bad.

Tube's in, looks good. Would anybody know if I should have the muffler shop weld the tube to the flange or cut a short bit of 1.5" ID pipe to weld to the tube(I believe thats how Suzuki and Ryca have done theirs)? Has anybody done anything similar?

I think I've seen it welded directly to the flange, and I would gladly edit this post with a link to the bobber build I'm referring to if it's okay to link to outside websites/blogs.

Also, to pull the air fuel mix plug, is 3/32" required or may I use a 1/8" bit? Alternatively I think I have some tiny self tapping screws in the garage.