I bought a Husky a few months ago and have been thoroughly been enjoying it in the time i have owned this wonderful machine.
*note, if not looking at how to do this yourself, just skip to the pictures*
I am a college student and haven't been working much because my place of employment caught fire and i have only been getting my paycheck from my boss' insurance (tips are a fairly big portion of my income, insert stripper jokes here), so I have been a little tighter on cash than normal... and I had to set up my bike a little bit more to my tastes (1 1/8 bar mounts, tall fatbars, sm hanguards, sliders etc), as well as fix other parts on this bike and myself after I did pulled my squid muscle and did a superman into a car going ~40mph. I have been rather sick of living with the 10 foot long and restricted stock exhaust, so while i wait for the pennies to trickle into my account to buy a full leo vince system... I decided to chop and gut my can! Another reason why I wanted to modify this exhaust before i got a new full system is that my HI-temp mx boot plastic was melting onto the muffler when i would do stand up wheelies on the passenger pegs. My gf had to be very careful to not let her inner thigh touch this muffler at any time just because of how the heat was retained in the restriction baffles inside the muffler, hopefully gutting it will keep it much cooler, because this exhaust was a serious hazard with how insanely hot this thing would get. hotter than the headers on some other bikes i have had.
First I took off the muffler and drilled out all the rivets.
The muffler is a big aluminum tube which acts as a sleeve with mounting brackets. Steel inserts with all the baffles and various restrictors thrown in there to make "chambers" for the exhaust. a definite no-go when you want free-flow.
The end cap comes off in a small piece and the header-side insert is what fills most of the submarine-like aluminum muffler sleeve. after ram-rodding the big side out, i trimmed it down quite a bit (so it was a couple inches longer than the end cap).
I then took my dremel to the orifice in the endcap and removed the 1" tube that ALL of the exhaust had to go through, all while retaining the ever so lovely husky "H"gunsight logo. I then removed all the steel wool behind a metal screen.
I took my sawzall and cut down the inner steel baffle tube (header side) so there were no more things to restrict the flow of gasses. There was a corrugated metal fixture inside the tube right where the header attaches to the insert. Think of a 2-3" strip of cardboard, rolled up into a cylinder, and then you look down the side of it, and can see light through the corrugated cardboard, that's what the exhaust had to go through. so i hammered that out with a crowbar as a chisel.
i then took my sawzall to the aluminum sleeve and cut it down 7-8 inches (so it ends an inch or 2 past the mounting brackets)
got my 4" belt sander, flipped it upside down, and sanded down the jagged edge of the tube until it was all smooth and level. I then sanded the melted boot plastic off of the tube 2.5"x8" with the belt sander, and then went over everything with 320grit and then 600 grit sandpaper to smooth it all out. i may go back with some 1-2k grit paper if i want a full polished can.
I drilled some holes to rivet the inserts back into place, and riveted them. The old rivet holes on the header side were worn out and needed re-machining anyway so i decided to double up on rivets and place new ones further into the sleeve.
The original exhaust:
The final product:
gunsight logo still there :thumbup:
still a little muddy from yesterday
and now I can ride around like this:
7-8" shorter muffler
2-3 lbs of material removed from the exhaust
Hopefully runs much cooler than before- safety hazard removed
no-more melted boot poo-looking stains on the muffler
noise is about equal to that of my 450 with a big-gun evo race series (spark arrested) system, maybe a little quieter, have to ride to find that out. I was surprised to see how well the exhaust sounded when i fired my bike up with no muffler on at all. I couldnt hear much of the typical hollow backpressure sound which one would normally hear on a bike with no muffler.
Hope this helps to anyone looking to uncork the muffler on their husky!
Now I can focus on getting a new supersprox sprocket setup to properly gear the bike! :clap: