Just got on to this site and have to give a thank you to the organizers...but now to my real topic. I haven't seen anything on modifying the stock exhaust but I've had my DS for a month and was underwhelmed by its low and mid-range. I took a suggestion by another local DS owner and removed the exhaust end cap, chop sawed the two 1" outlets off and then took a grinder and removed the internal portions as well. I left the spark arrestor intact and since then have been experimenting further. I've now got a single 1 3/4" hole (had to do a bit of backfilling, a MIG comes in handy) and the noise is less than a CT pipe I heard and the power is great! Where I was shifting down coming out of corners stock, I now leave in a gear higher and roost my way out. If this would have been an aftermarket pipe I would have been more than happy with the results and I didn't have to pay $400!!! You only save a pound and it still looks close to stock. Just seat of the pant comments but riding is a lot more pleasurable (plonking along or gassing it).

Stock toe-in was 1 1/8" and now have it down to 1/8" per an earlier suggestion in this forum (thanks to the guys who experimented with that). More stable and confidence inspiring. Just some cheap fixes and feedback for you all.

I want to add braided brake lines on the front as they're not up to the precision of what I'm used to on X-country snowmobiles (Brembo's and Wilwoods).

 

Thanks for the info. My DS is only 3 days old, so I'm not ready to cut it up yet,,,give me a week. I did a similar mod to our Polarises, opened up some internals, a larger tailpipe, worked pretty good and not much louder.

 

Bombard, you don't mention any carb adjustments after modifying the muffler cap, didn't require any? Do you have a 2000 or 2001? I think they changed the jets for the 2001's? The muffler end cap on my 2000 isn't looking so good, the finish is bubbling and looks milky, I just may modify it as well. How about air intake, stock, air box lid on or off?

 

a friend of mine has a pingery exhaust tip sounds real similar to what u have done with your tip. But I bet yours fits alot better the fit on his tip has gaps almost all the way around it and one of the holes didn't even lign up. However with some high temp silicone he now has no leaks as for jetting he did none but his ds did run a little rich in the first place. Here's the kicker he spend like 70.00 on the tip seemed a little outragous for what it is but it does run better.

 

I've got a 2001, which I believe comes with a 165 main (needles, etc stock also). The 165 is still in there and plug colors look good at 2200' and 50 deg. F. No mods to airbox and the lid is on. Runs and starts very well with no lean surging, etc. I

I was running dead stock (including pipe) at the same elevation and temperatures of -5 deg F so it definitely would have been fat anyway at plus 50 with no mods. I'll probably rejet when it gets cold again in the late fall but otherwise no problems.

As for fit/finish, it fits as good as stock (naturally)which is good as the packing can try to sneak out on a bad fit otherwise. Right now it has a welded/ground finish but I might finish it off a bit better. I was still tweaking the exact hole diameter but I think I'm done tinkering at 1-3/4" so its now time to make it look better.

This is by far the best cost/performance mod I've ever done on a machine (cars,sleds,bikes, ATV's).