I been wanting to shorten my Stock muffler for some time. I just think it's so long! (probably cause I'm dreaming of a 2010 RR ) So I searched threads on forums and mostly found bits and pieces on info, but nothing to make a good decision on. So I decided to find out the hard way.

I like the sound of the stock can at higher rpms, but at low r's it's so tame sounding, I wanted just a little more, but nothing loud.

So I cut off 4 inches from the end and it's way too loud now. But it does sound cool. The young guys will love it!

I think I need to fashion some kind of baffle for it? Or pack it with muffler packing? There have been many people chiming in on this subject but I couldn't find a definitive 'how-to'. If someone with experience could help me with that, it would be much appreciated.

Here is my '02 954 after the can comes off


Here is the can. I took a sharpie and made a line to cut.


I used a grinder to cut the muffler can, but didn't realize there is 2 pipes inside that need to be cut. And the grinder blade doesn't reach. So I borrowed my buddies sawzaw and it took like 34 seconds. Using the grinder was a bitch. I suggest you get a sawzaw to make this super easy!


Here is what it looks like inside the can...


And here is the finished stock muffler shorty style. I think I cut too much though. Should have just done 2.5 inches. At least if I wanted to cut it more I could, but I can't go back!

 

im thinking about doing that too mine, did you loose any power or anything?

 

i cut mine down, just above the mounting bracket. however, i put mine almost all back together (minus the stuffing). it sounds great. i cut it just a few inches at first, then a little more, and a little more after that, until i got down almost to the bracket.


if you put the inside back plate back on, it will make it sound much quieter. thats what these pictures show (even though its much shorter than yours). for example: at bike nights, i cant hear my bike over all of the harleys and ive had toll attendants say things like "wow, finally a bike thats quiet" (which was after a group of harleys and sportbikes). the inside back plate also keeps a lot of the backpressure, so you won't lose a lot (if any) power. mine has absolutely NO baffle in it. there is a hint of "rasp" sound from 7k to 7.5k, but aside from that, it sounds perfect like any other aftermarket exhaust. also, the inside backplate wont let as much moisture in (in case it's raining).

 

No power loss on mine. I like it now. Sound, looks, it's sweet. Still a little loud though.

I will try to put the inside plate on like Conrice says.

Conrice<-- How did you separate the plate from the muffler housing you cut off?

 

it is its own seperate piece. so twist and pull (push from the other side) and it should come out. once that's done, you'll see the rivet holes, just line everything back up and you're ready to re-rivet the exhaust back together.

 

it doesn't really get more simple than that. this is one of the easiest things you can do to your 954. i dont have any more pics from when i did it, it was a long time ago.

steps:
1) un-bolt can.
2) drill through rivets (not too big of a bit though, you don't want to widen the rivet guide holes).
3) un-pack exhaust (just pull all that junk out).
4) cut exhaust tube down to desired length (sawzaw for sure).
5) line up the end plates, and drill hole into can for your new rivets.
6) re-rivet the end plates back into the can (stainless steel rivets) .
7) re-bolt can back onto bike.
8) go ride.

 

The insides of my can doesn't come right out. Its all welded together. I will have to grind the weld down on the cap to take it off, very carefully so I don't take too much off the cap and can use it, and it's still looking good. I will post pics when I do it.