id like to cut every thing off inside also and just leave the two on the outside, im not worried about noise i live in the country but i am concerned about having to rejet it, would i have to change my main and my needle and my needle jey? and the clip position? thanks fellers

 

Dunnycat i did not weld a diff piece of pipe on mine i simply cut everything out of the inside so it was flush and left the two stock holes...it is not to loud but has a good sound and did give a little bit more power all i did was move the clip position everything else was left stock and it runs good

 

Hey, Jackass I would think you would want to change your main jet for sure,I changed my stock 165 to a 167.5 with the stock pipe and I felt a change and the glowing header isue went away.

 

Dunrider, Did you change your main? I need some training on the needle position thing. I did a power kit on a polaris a long time ago and had to change the needle, but I guess I really dont understand that part.

 

no i did not change my main just moved my needle clip to the second lowest position

 

Ok Dunnycat, i cut out everything. I Tried to keep the cuts as close to the welds as possable. Don't make the whole any bigger than it needs to be. Basically cut right around the welds on both sides of the endcap and keep working at it until it comes out. Then, i took the oval stainless tip from the auto parts store and traced an outline with a scribe on the front side of the endcap. Then, i used my diegrinder with a carbide burr and just keep cutting it open until there was just the traced line left. Then sqeeze the tip inside, it should be tight. Don't open it up too far. Just keep going a little at a time until the tip will sqeeze in the endcap. Push it in until the desired depth, and have her' tigged up. I cut several slots into the backside of the tip, (the part inside the muffler) so i could bend the "FINGERS" that are left from the cutting, outward until they meet the inside of the perforated tube in the muffler. It works really good too. I just did my bud's Baja, and he loves it. It's on my pics page if you wanna check it out. But, it ain't quiet either. You WILL know something has been changed. It's ALOT louder than stock. But, i think loud bikes are safe bikes, so, no biggie to me. If you don't wanna deal with the mess, ship it to me and i'll knock it out for ya' for a small fee. Tip, welding and everything. It looks so sweet, you'd swear it was factory. Let me know. You won't be disapointed.