[spewingjason]

Want to sell it to me? I’ll give it a go, maybe I’ll play with some baffles in it or something.


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[CJ7Pilot]

Here's an easy mod I found on an XT forum... the muffler is just like ours:

Z1's super duper stock exhaust mod...illustrated | Upgrade Projects | XT225+250 Rider's Group

When I bought my bike, the stinger had been cut off the back of the muffler, and the interior baffle already had some holes punched in it, so I cleaned it up with a hole saw.

It was pretty loud, and kind of annoying from the rider's perspective. I welded a new stinger on the back, angled downward a little bit, and it made quite a difference while riding! It's still louder than stock though.

It's all in my day mods thread, if you feel like poring through it: http://tw200forum.com/forum/performance-customization/37993-steves-87-day-mods.html

Cheers! ccasion14:

 

[DougDotyTW200]

Sold and shipped to Jason, above funny how things work out. ..........

 

[PlacerLode]

Here's an easy mod I found on an XT forum... the muffler is just like ours:

Z1's super duper stock exhaust mod...illustrated | Upgrade Projects | XT225+250 Rider's Group

this is the best sound mod method I know of it does give the stock pipe a bit more roar

DG and FMF are both great products quality wise just too loud for my tastes

I still have a pristine 2017 FMF stainless pipe for $200 shipped USA

 

[SportsterDoc]

I guess 25 years of Harley’s just wore me down on noise.

ROTFL
When I was a kid (12?), I replaced mufflers with straight exhaust on garden tractors.
I soon outgrew the need for noise, although I removed a few diffusers on early Hondas.
...don't want to be silent alongside a 4 wheel vehicle.

 

[SportsterDoc]

this is the best sound mod method I know of it does give the stock pipe a bit more roar

and the recommendation for anti-seize on the cap screw is very good advice. On a Sportster forum, that is referred to as the gronk method.

On Sportster shorty dual exhausts, an 8" long 1/2" drill down the center makes a reasonable improvement. Just not easy to undo.

Probably never get another Sportster (new model frames too low to the ground), but still have the 8" long drill bit.

 

[littletommy]

When I was a kid, I had the loudest baddest Harley on the block. I put so many clothespins and playing cards on my bike's that you could hardly move the wheel. It just roared as I dreamed of the future when I could really have a motorcycle. I still love the old school Harley sound, but I'm done with Harleys. (I think) One of my HD friends is running drag pipes with no baffles and I almost can't stand to go anywhere with him, it's just obnoxiously loud.

 

[SportsterDoc]

When I was a kid, I had the loudest baddest Harley on the block...

Define "kid"

My mom passed last October and my dad moved into an assisted living facility.
My sister and wife went through 1/2 a century of accumulation from living in the same house since ~1954, married 71 years.
Wife brought home a ton (slight exaggeration) of photo albums.
Two are of me on my dad's Harley, circa 1951 (age 4), one with my paternal grandfather (died when I was 13).
I'd share, but I first need to psych myself up for the onslaught of jokes relating to how my mom dressed me.

 

[DougDotyTW200]

I am with LT, "I think I am done" I went through it once before and lasted one season, switched from Ultras to a road king and fell in love again for a few months. I had 9 of them over the years I really think I am over it now. I got tired of all the 1%'er wannabes trying to buy a personality off the accessory wall at the dealership. My motorcycle respect is with the real riders these days, the guys that really ride through the cold and rain for the love of it, 10's of thousands of miles a year. Most are riding BMW's a few Goldwings and these days the dual sports that are accumulating a lot of miles too. I never did, I was just a fair weather guy too. Pushing the season on this little TW more just for fun that ever before.

 

[Trail Woman]

I prefer to hear things. Either to know whats coming or that I'll retain my hearing for years to come but I do like the sharper punch of the muffler with my hand a few inches behind it. Too bad I can't drive it like that. I'm also not interested in making so much noise everyone knows I'm driving.

 

[grewen]

Is the DG pipe the one to get? Could use some recommendations.


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i found the DG to be a good replacement. with my modified silencer it wasn't much louder than the stock pipe and just a little deeper in tone. the DG did have to be repacked after a year

 

[Trail Woman]

Does drilling out the stock muffler like that require anything more then an idle adjust? It's sounds like it may require new jetting....

Otherwise a deeper rumble with more power and no more noise sounds great.

 

[PlacerLode]

Here's what the spark arrestor looks like once removed. You can see there is little or nothing actually holding it in place once you remove the single retaining screw but they can stick like crazy. A little tapping from various angle using a rubber mallet is a good solution especially if the muffler is still bolted to the bike. My muffler was off the bike so I grabbed the pipe assembly and tapped the spark arrestor on a rubber dock bumper to "knock" it loose

Now looking inside the muffler you can see there is a front chamber wall about 8" deep and thats what you drill a hole in to increase the loudness. You could start with a small hole maybe even 1/4" diameter (even multiple small holes) and work your way up to a 1.5" holesaw for max volume

 

[Fred]

These drilling mods seem to defeat the spark arrester feature required in our National Forests. It is not like you will likely get caught, and I certainly won't tell. Just be aware of mildly increased chance of ejecting hot carbon when riding in dry grasslands or other flamables.
Personally I like the ability of several stock muffled TWs riding together to throttle down and have conversations from bike to bike without stopping. "Yo Bro! Let's stop at the next shade for a drink and check the map."

 

[PlacerLode]

Fred (sigh lol) this mod does not defeat or even touch the spark arrestor
will somebody stop by Fred’s place and check him for a stroke today please
or see if an alien spaceship has landed in his back yard possibly taking over his likeness

 

[SportsterDoc]

These drilling mods seem to defeat the spark arrester feature required in our National Forests. It is not like you will likely get caught, and I certainly won't tell. Just be aware of mildly increased chance of ejecting hot carbon when riding in dry grasslands or other flamables.
Personally I like the ability of several stock muffled TWs riding together to throttle down and have conversations from bike to bike without stopping. "Yo Bro! Let's stop at the next shade for a drink and check the map."

Fred, I very much appreciate your sentiments, but

1. This was in post 2: "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.

2. As PlacerLode pointed out, the "gronk" mod of opening up the muffler section, ignored the arrester mod and allows reinstall of the stock spark arrester.

 

[grewen]

Z1 mod

 

[jtomelliott49]

My '87 has the rusted out underside close to the rear of the muffler. My '99 does not. My '87.....brap!@!@!@ I kinda like it.

 

[E1320]

My TW sounded terrible when I wound it out stock and it was so lean. So I took the spark arrester out took a 1"3/4 hole saw drilled out the blockage in the muffler. I reinstalled the spark arrester. Than I pulled the out the baffle out of the airbox. I changed the main jet from a 162 to a 170, I put a shim under the needle and turned the pilot screw out 2 and one half turns. The bike sounds a little louder at idle and cruising, but it sounds real good when you wind it out or cruising at highway speed. In the woods its still quite when cruising until you open it up. It starts up much better now.

 

[Wormspur]

The back cap 'blew off ' my muffler on my ride to work. It was still attached a little bit but I twisted it off. When I looked inside there was nothing! ( one of the little flow deflector ~shown above in the spark arrestor~ was jammed in the tailpipe) Without the cap it is too loud to ride.

has anyone repaired one of these? Can I buy a core tube and wrap it in matting and weld the cap back on?
I am basically ready to buy a new stock exhaust but at over $300 i must consider some DIY .

Let me know what you think.

Thanks.
--matt