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Thread: Modding stock exhaust

  1. #1
    Senior Member spewingjason's Avatar
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    Modding stock exhaust

    I donít want it loud, and I know there is no performance gain to be had, Iíd just like it to be a tiny bit louder so I feel less like Iím riding a scooter. My 87 has a kinda beat up muffler at the end, and it is considerably noisier than my 95, but I like it. Itís not loud,
    Just enough to know itís doing something. My 95 is QUIET. Iíd rather hear a little exhaust over my chain going over the slider, you know. Surely someone here has a similar feeling and has played with their muffler some. Any tips? Iím a competent welder so if I put a hole where I shouldnít have, I can patch it back up.


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  2. #2
    Senior Member SportsterDoc's Avatar
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    If you do not need a proper forest service approved spark arrester, you can remove, cut off the cone in the inside section and reinstall.
    Try it first without the arrester, at all, to get a sense of the decibel difference and tone.
    I do not think I posted photos of doing that on the TW nor the XT250.
    Save the cut-off section, as it can be welded or brazed back on, if you do not like it.

    An impact on the Phillips screw holding on the arrester is recommended...even new.
    That and a vise plus hacksaw are the only tools needed.

    I do not like loud (obnoxious), but do prefer audible.

    As much as I enjoy experimenting, I also like to be able to revert to stock.
    The attached photo is of my CB1100.
    I drilled the 3 holes (1/2").
    Liked the sound accelerating.
    Very much liked the rumble decelerating.
    But did not like the sound at idle...sort of a fluttering.
    So, I made blocking plates, drilled and tapped (10/32") a pair of mounting holes for each 1/2" hole and blocked my experiment.
    They are covered by a stainless steel cone.

    The air box mod on the CB1100 worked very well, but I saved the section I sliced off, should I want to reapply with crazy glue.

    Exhaust mods-half inch holes.jpg
    Snorkel cut.JPG
    Snorkel mounted.JPG
    Last edited by SportsterDoc; 02-26-2018 at 05:43 PM.
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    2014 Honda CB1100
    2018 Yamaha XT250
    2016 Moto Guzzi V7 II
    2017 Yamaha TW200
    2012 Triumph Bonneville
    2002 H-D Sportster 1200 Sport
    2003 H-D Sportster 883
    1976 Honda CB750F
    1975 Honda CB360
    1970 Yamaha CT1
    1972 Yamaha CT2
    1972 Yamaha AT2/CT2
    1970 Honda SL350
    1970 Honda CL350
    1967 Honda CL160
    1967 Honda CB160
    1962 Honda CA110

  3. #3
    Senior Member spewingjason's Avatar
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    Ok. Thanks doc. Just now got the Phillips out. It came out without too much trouble. Havenít gotten the baffle to wiggle yet.


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  5. #4
    Senior Member SportsterDoc's Avatar
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    Quote Originally Posted by spewingjason View Post
    Ok. Thanks doc. Just now got the Phillips out. It came out without too much trouble. Havenít gotten the baffle to wiggle yet.
    Welcome!

    I get a lot of use out of my rubber mallet...just don't smack so hard as to dent anything.
    2014 Honda CB1100
    2018 Yamaha XT250
    2016 Moto Guzzi V7 II
    2017 Yamaha TW200
    2012 Triumph Bonneville
    2002 H-D Sportster 1200 Sport
    2003 H-D Sportster 883
    1976 Honda CB750F
    1975 Honda CB360
    1970 Yamaha CT1
    1972 Yamaha CT2
    1972 Yamaha AT2/CT2
    1970 Honda SL350
    1970 Honda CL350
    1967 Honda CL160
    1967 Honda CB160
    1962 Honda CA110

  6. #5
    Senior Member spewingjason's Avatar
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    Grabbed it with my vise grip attachment on my slide hammer. Three whacks and it was off.


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  7. #6
    Senior Member Peterb's Avatar
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    Pics and a sound clip after would be cool.
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  8. #7
    Senior Member DougDotyTW200's Avatar
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    I agree with both of your tastes on sound, I just installed a DG O Series and it is too loud without the quite baffle that they sell seperate and I do not have. Considering making my own as I saw a fella do this on on youtube with the exact same combination and it toned it down quite nice.
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    2016, stock'ish and a 2003 Starting on a 225 or bigger 6 speed build as a spare for now and install later when done and ready on this bike.

  9. #8
    Senior Member spewingjason's Avatar
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    Modding stock exhaust

    I cut the spark arrester out, didnít make a huge difference really. A little louder but not much.


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    Last edited by spewingjason; 02-26-2018 at 07:10 PM.
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  10. #9
    Senior Member spewingjason's Avatar
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    Thinking about hole sawing the tiny 3/4Ē tip out and welding a 1Ē or so tip in. Anyone got a spare end cap I can buy when this turns out like crap? Lol.


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  11. #10
    Senior Member spewingjason's Avatar
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    Also, I think there may be baffle in the muffler loose and rattling. I may be in the market for an entire muffler anyway, so what are some aftermarket pipe recommendations?
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