Ok, I have a spare stock endcap that I was going to play with. does anybody have any ideas what I should do?

Also, I have a modded end-cap too, and If I wanna make it louder, to show off, and maybe get a little more power, can I take the muffler baffle thingy, and the packing out, and just run it strait? Open, or with an endcap? Will it hurt it?

 

Adam~
I have a modded end cap that I made myself. It is VERY crude and very loud. I basically just cut the dual outlets out of the stock endcap and brazed in a piece of 2.5" exhaust tubing with a small bend on the end. The braze didn't stick to the stainless endcap too well so I used JB weld over the brazing to completely secure the exhaust pipe. For sound suppression, I tried a method developed by Fourlix. The exhaust tube extends about 10 inches into the muffler. I cut slits into the exhaust tube so I could bend flaps of metal down into the middle of the tube. I think it helps reduce the sound a little, but I know it is a LOT louder than the stock exhaust.

 

One more thing...once you start playing with these end caps, be sure you are doing jetting runs every once in a while. I have found a Mikuni 180 main jet to work well with the stock air filter and no airbox lid. Also I have the needle clip on the 5th notch and the engine feels very snappy like this.

 

I was thinking of cutting out everything on the back side of that stock end cap off so its just two flush holes and leveing the out side of the cap alone so it would be louder and flow a little better. But still look stock. Thats if you wanna go sleeper mode.

 

hmm, sounds good, I might just do it, but nobody's answered my other question yet. Can I take out the stuff in the muffler, and just run it open end, or with just an endcap?

 

Less Sound = More Ground
Don't just rip everything out of your muffler to get louder, do it right and get performance without being a poster child for loud obnoxious ATV's.
We've learned a bit collectively about this end cap thing, and the first thing is that the stock DS muffler is actually a pretty good design, except for the end cap.
....What's good about it is the perforated liner inside the muffler. It's
shape expands like the first half of a reverse cone megaphone. The fiberglass packing doesn't hurt anything either. So restrain your efforts to just the endcap and help us keep riding areas open.
....Knutz just did some dyno testing of two of my endcaps and one of his as compared to a stocker. With a CDI and rejetting he got 52 hp out of a stock DS and 8 more hp in the mid range. One of my endcaps did worse than stock,(the one with a 1.5" outlet)and the other did the same as Knutz on the top end (2&quot but without the big midrange boost.
....Knutz's endcap used a 2.5" tailpipe. We both took advantage of the near reverse cone design and put a small reverse cone on the inside of our endcaps. But I put a restrictor into the endpiece forcing the exhaust gases to go out and back through the slots. That's where Knutz's more open design beat mine in the midrange. Slot the tailpiece inside the muffler, but keep it a straight thru, open pipe. The slots will kill some sound, but not hurt the flow much.
I used the same slot design on both, but the 1.5" used the stock spark arrestor with no reverse cone.
....So, I would reccomend a 2.5" tailpiece going into the muffler 4-6 inches with a small reverse cone. Slot the tailpiece, but leave it open.
It will be plenty loud, but not as loud as a slip-on. Performance will be as good as anything you can buy. The only reason to buy an aftermarket exhaust is for looks and weight savings. I am still messing around with the quiet core on my HMF, which works great on my son's Raptor, but still doesn't quite do it on the DS, at least not with the quiet core, which I have already heavily modified. But it looks great and weighs pounds less than the stocker. The CDI is a must
BTW.
A Dyno run would be really nice....
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Very good reply Fourlix and oh so true, LESS SOUND EQUELS MORE GROUND
bearman