I've been riding a '02 Savage for about a year now with the Hartman exhaust mod, the only change I made was turning out the idle air mixture screw. The Hartman mod was a fair amount of work and involved cutting out and welding the end of the muffler back together after pulling the baffles and repacking it with fiberglass. If you do the Hartman mod start the bike outside, not in a garage, the fiberglass that is used to repack the muffler has a lot of dust and small pieces that will blow all over the place!!. The Hartman mod is a real improvement over the stock sound and gives better performance but if you can track down a Sportster muffler it will be even better for the tone of the exhaust, performance and look. You will need an adapter that's bent at about 10 degrees and is maybe eight inches long to go between the stock pipe and Sportster muffler and a piece of flat stock that will go between the stock muffler mounts and the tab on the sportster muffler. Most muffler shops can bend up the adapter for around 10 dollars. Take the pipe, stock muffler and sportster muffler in to a shop and explain what you need.  I just changed over to a Sportster muffler and am real pleased with it.
   The carb mods that i've done so far are replacing the white spacer on the needle with two #4 stainless steel washers that I cut down to a smaller diameter using a drill and emery cloth. This fattens up the midrange and really helped with the modified stock muffler. Since I've installed the sportster muffler I rejetted from the stock 145 main to a 152.5 main but haven't been able to get out to pressure test it yet. Also just installed the K+M high flow stock type replacement air filter. Good luck with your '02, what color is it? mine's got the silver paint job. Ride Safe

Here are a couple more tips on the Hartman mod. The end of the muffler is pretty thin sheet metal, if I was doing it again I would cut the end of the muffler out using a hole saw not a torch. Stick a piece of wood in the exhaust pipe at the end of the muffler to keep the hole saw center drill from wandering while cutting. It will be a lot easier to weld it all back together by just filling the hole saw cut instead of dealing with the damage a torch can do. The end of the muffler is made out of two layers of sheet metal welded together at the spotwelds, you need to cut through both layers with the hole saw or torch, I would recomend cutting through at the spotwelds, that should give you enough metal to weld it back together again. It's a fun project and is easier with the muffler off the bike, I did it with the muffler mounted on the bike but I never said that I do it the easy way .
 If you check out the tech section you will see some good pictures of the carb in different forms of disassembly. There is a good shot of the white spacer on the needle. The hardest part of working on the carb is getting the stock philips head screws out of it, I had to use a miniture pair of channel locks and could only turn the screw about 1/16 of a turn at a time. If you do decide to work on the carb replace the stock hardware with allen heads, it just makes life a lot easier.
 The stock main jet in all the newer Savages is a 145, That's what I had in my '02 and that's what is in yours. The deal with the white spacer is that it makes the bike run a little lean in the midrange. Some riders pull the spacer out completely with no problems, others say without it the bike runs rich, that's why I replaced it with the washers that are 1/2 the thickness of the original white spacer. If you are planning to work on your bike you should get a Clymer's manual, it's worth the money. Good Luck and Enjoy you Savage

Lots of questions.
The 2 hoses coming from the floatbowl are breather hoses and go in the square tube of the frame.

I presume you have the carb off. The 4 screws are VERY tight but have to be undone before you can get at the spacer. Look in a previous post of Greg_650 for a breakdown of parts.

Ronayers.com microfiche might give you the answer if the original carb. is installed.

Greetz
Kropatchek

marty62253,

You do not have to remove the air box, but you do have to remove the battery and battery box, or at least I had to.

Obviously, you also have to remove the large tube from the air box to carb air intake and the air/fuel mixture tube from the carb to the engine.  It is a tight squeeze.