OK, It's obvious not too many of us care for the sound level, tone, or looks of the stock exhaust. One of the issues that bothered me the most was the tiny outlet! It just looked terrible! I think I started this whole thing by drilling the first baffle plate with a 1/2" bit and posting about it back in January when I got the bike. I've done "all" the mods from top to bottom and quite honestly the bike works great! I just couldnt take looking at the little outlet in the muffler. I know we have had many discussions around performance increases with the aftermarket systems and such. So to make a long story short, after much comtiplating and thinking, I did the following, which i must say am extremely please with.
1) Drilled out the stock/existing tube with a milwaukee 1" dia. "deep" hole saw.
2) Using a piece of 1" iron pipe, turned the I.D. to .900" and cut the tube to be just a bit longer than the stock outlet tube.
3) Threaded in the new Tube into the muffler. ( This work really slick as you have no way to weld the inner support and the "pipe" thread locks up nicley.
4) Welded the new tube into the stock muffler and repaint
See photos below.

I know I'll be getting lots of "feedback" about modifying a stock muffler opposed to spending $500.00 on a aftermarket system ( I can not bring myself to see that amount of cash being value added for the minimal gains. personal preferrence. ) Plus using a piece of threaded pipe for the new outlet. I truley believe the small outlet to be the biggest restriction in the exhaust system. The catalyst as most cats is not restrictive to flow as many believe although is does add a couple of pounds. As stated in a different post, the factory invests a huge amount of resources to develop a exhaust system that meets the performance targets as well as the emmisions goals. This doesn't mean they are perfect, but not as bad as we think they are.

I will tell you the finished product for both sound and visuall effect is really nice! It's a great running 250cc machine! and not to be taken for anything else.

If this post helps out at least one of you, then it was worth my time to share what I've done.

Sorry I don't have a photo of the finished pipe but I'll get one this weekend and post it.

OK I could only get one pictire to load, how can I get more than one in here ???



[IMG]local://upfiles/1026/0B09F9D9D2AB48819053E3B28D8CCBE9.jpg[/IMG]

 

Stock vs modified tibe comparison.

Stock ID = .5" Area .196"
Modified ID .9" Area .636"

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2nd photo of stock vs modified outlet tube

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Modified tube installed.

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Hey man more power too you for doing what you like doing and saving some money in the process. I just like to have my stock muffler in case it ever needs to get this so called inspection. I still have to go take the driving portion of the test to get my license, I wonder if they will bitch about my White Bros. exhaust, hmmm??

 

Looks very interesting, Don, nicely done. What differences have you noticed in terms of sound? It is a "better" sound than stock? By that I mean fuller, not just louder. One thing I like about the Muzzy recordings is the deep throaty sound. I'm pretty sure modifying the stock muffler is not going to reproduce exactly that, but does the sound get better overall?

How about performance - can you judge any differences in that regard?

I'm also in the market for a pipe upgrade - doesn't have to be a Muzzy. But I don't want something that is too loud. Performance would be good, but I'm getting good performance now with the standard low-cost/free carb/airbox/pipe mods so that is not of prime concern. I think a lot of people are in this boat.

But then again, everyone who has bought a Muzzy has not been disappointed, so that is influencing me also. I'm personally a bit sensitive to the noise level - I don't want to have to wear ear plugs, nor do I want to draw a lot of attention to myself if I'm riding somewhere that maybe I shouldn't but it is tolerated because the bike is not too loud now, but wouldn't be if I upgraded to a Muzzy. I wish I could hear one in person without dropping the $400 for it.

At any rate, this is not something I have to decide right now. My bike is running good. I've got new tires on the way and a few other goodies to keep my busy. A pipe upgrade or similar modification to yours may be in my near future though.

 

I will take and post the completed installed photo after the weekend.
The bike is up north at the lake!

The sound quality is VERY nice in my mind, not at all offensive, but just nice.

I can do a video clip for the sound but have no clue how to post it.

Can anyone help out with that.

As for a performance gain, maybe a little, by no means a day and night difference. Letting it breathe a little is still the best for the stock motor. Any more than that, one needs to do Cam, Compression, Port work ect to gain the full effects as everything works together.

 

Just PM'd you with the details.

 

With anything but stock you will be heard, even with quiet core and the spark arrestor in it. But heres the payoff, you want to be heard with that smooth sounding bike. Now with 6 plates in my bike it doesn't sound as aggresive as before but it still has a sweet sound to it, before I needed earplugs because it was seriously that loud.

 

Here's what it lokks like when completed.
Nobrakes will be posting the Audio/Video clip soon.
Don