I've been reading here about some modifications to the stock muffler in which you can cut a hole in the end of the muffler and weld on a small pipe there. There was also some mention about cutting the ends off the muffler and removing some or all of the internal baffles.

I'm planning to make the end pipe modification, but I'm wondering if there's any benefit to messing with the baffles inside the muffler. I don't want it to be much louder than normal, but I will sacrifice some noise for more flow. Over on the Kawasaki forum, there are guys that drill several holes all the way through their baffles to increase flow without much noise increase. I was wondering if that would be a worthwhile modification on the Polaris as well, and if so, how many internal baffles exist on these mufflers?

-Mark

 

Hi Mark do a search on mufflers in here Ive posted a pic of my 700 muffler I reworked...

 

Hey, Bill! I saw your picture earlier - you did a good job on it. Looks stock. As it turns out, I just finished the modification on mine. I used a piece of 1 3/4" pipe on the end instead of 1 1/2", and I cut the stock exhaust extension off and patched the hole. While I had it off the bike, I also opened up the first baffle vents a little with a screwdriver.

I haven't had a chance to ride yet to see how it feels, but it sure sounds different just idling and revving. It's a little louder than I thought it might be.

Click here to see some pictures of it.

 

Hey Mark that looks good...When I did mine I went with a KnN filter and a bigger main jet in the carb...

 

Hey Mark V-

Nice job. Quick question though.....did you cut through the second piece of metal into the muffler? The one pic makes it look like you only cut through one layer.

I did the same to mine. Used 1 1/2 pipe and a hole saw. Cut through both layers of muffler.

I am at about 650 feet in elevation and had a 162.5 main stock. I added a K&N and went leaner. So when I made the muffler mod I went to a 165. Way too lean, plug looked like it had just come out of the box rather than the head. I went up to a 170 main, only jet the dealer had. Right on the money now. While it is louder, it feels like it has more mid range power. My heelclicker should be here next week.

Going riding tomorrow with the new GPS, will report back on Monday.

SpruceDeuce

 

No, I only cut the outside. The rear baffle of the muffler already had a 1" or so hole in it, so I just left it alone. It appears that the pipe that runs through the center part of the muffler wasn't any larger than that last hole, so I didn't see any need to enlarge it. I can't wait to ride it to see how different it feels. I need to get some jets and a better air filter so I can tune it up like you have.

-Mark

 

Well, I took it out for a ride last weekend, and it definitely breathes better. The 700 has always seemed a little restricted with all the stock components. I cut the air intake snorkle just before it necks down into the smaller tube, and I also have the muffler modification. It does feel "freer" now.

However, the exhaust is a little too loud for my taste. I think I'm going to sell the stock muffler and go with an aftermarket setup. I'd love to have something that has a deep, throaty sound, is less restrictive to the 700 CC engine than the stock muffler, but isn't much louder than stock. Any suggestions?

 

I test rode a 700 with the Hot Seat header pipe and muffler. It also has the hot seat air box mod, much more open. Runs like crap. I think they have opened the air box too much and the carb isn't getting enough vaccume.

I didn't like the sound of the hot seat pipe and muffler. Very muffled sound, not crisp.

SpruceDeuce

 

How loud was it compared to the stock 700 muffler?

 

It really was not much louder, but ut was $400.

SpruceDeuce