Finally got around to finishing up my stock exhaust mods.

I used a exhaust tip from a KX400 ATV and hacked it down to fit, blowtorched the straw out of the stock exhaust and with alot of paitence and a keen eye for detail, I prevailed


Heres the hole that i cut with the torch and then dremeled out to give a snug fit to the tip.












Heres the tip cut down, forgot to take pics of the before, but it was quite a bit larger in diameter.






And heres the 90% finished product (gotta rivet it on).





I think it sounds really good, not much louder than stock but with a nice mellow throaty thumper sound when you get on it. I'll try to get a video so you can hear the sound when its not so windy outside. Personally i think it came out pretty good for a hack job using only a blowtorch, angle grinder and a bench grinder


UPDATE: Video Uploaded

09 KLX250S Custom Muffler Sound - YouTube

 

looks good. will it pass the stick test?

 

The who what ?

If you mean the spark arrester test, no. Its really not a big deal to me since i ride mostly on dirt and fire roads or private property, or on the street.

It would pass if i had not already drilled out the spark arrester "baffle" like so many other had suggested when i first got my bike. I really knew better but the stock can is so ****ty in stock form that i was looking for anything at all to increase whatever little bit of performance i could.

As an aside, the bike feels much better now that i've uncorked the outlet, i will pretty easily power wheelie in first with just a little bounce where before you needed a forklift to raise the front end off the ground.

 

Looks nice!

 

UPDATE: Video in first post.

 

Great job!

Looks nice and doesn't sound too loud, but a nice throaty sound.

 

thanks, i still want to do a muzzy or leo vince later on, but for now its a huge improvement over the crappy stock can.

 

Is that the cat Im seeing inside the can?

I posted on doing something like this a bit ago, so glad to see someone did it and post some pics... thanks!

If you cut the straw off the back, you will still retain the spark arrestor if it wasnt drilled previously? Do you think this mod will increase the flow of the exhaust by just cutting off the very back and not drilling out the spark arrestor?

David

 

I dont know where the cat is inside the can. I could not see it.

yes as long as you haven't drilled the spark arrestor out previously, cutting the straw out of the end of the muffler should not affect it at all.

drilling of the spark arrestor is pointless IMO. After cutting the end of the can off and seeing how everything was designed, i've come to the belief that exhaust flow is restricted by the end cap and the crappy little straw only.

 

Nice job.