SuzukiSavage.com - Replacing Exhaust?

gandalph40

Ex Member

Replacing Exhaust?
11/18/04 at 11:05:41

How much trouble is it to replace either:
a) The entire exhaust system
- or -
b) Just the muffler?

I've seen Savages that still have the flared heat shield with an aftermarket slip-on and that look doesn't appeal to me, so I guess part of this question is, "can the flare be removed?" I guess I'm just looking to other folks that have done this before.

Thanks.

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Smoknweelz

Ex Member

Re: Replacing Exhaust?
Reply #1 - 12/01/04 at 09:10:40

I'm "new" here also and was wondering the same thing... I don't mind the stock heat shield so much, but, was wondering if anyone had a link to a website (I've seen "Jonline" good pics, but not what I need), or even pics they can post of thier own removal and install, that would give me an idea of whether I can do this myself, or if I should pay to have it done... I can use a ratchet and screwdriver, but that's about it! Roll Eyes

Also, I keep hearing that you have to "re-jet the carb" after modding the exhaust.. where do you get new jets, how much, and how hard are they to instal, and do you really have to, or can you just remove the "White plastic spacer" i've heard about, and "Remove the plug and adjust the air fuel mix that is hidden" and that be enough to compensate?

Also In the Technical area, Red2K1 responded to a question in the Muffler Sounds thread with...

Quote:

hammyo,

I run a Jardine on mine and it is loud. Mine sounds much different from the file -- mine is much deeper. Tuning the engine, as does using the choke, makes a big difference in the exhaust note.

Really wondering about what he meant by "Using the Choke" Can someone please explain?

Smokn~ 8)

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cphilip

Ex Member

Re: Replacing Exhaust?
Reply #2 - 12/01/04 at 17:20:22

Its really pretty easy. If you can turn a ratchet and hold a box wrench then your about done. Just a few bolts and such to losen and retighten. I found it best to take the two exhaust header bolts lose from the head of the motor so I could flex the new muffler into place but otherwise most of its the bolts and stuff hidden by the shield itself. its like a half hour job overall first time you ever done it. very easy install really. Don't be too shy about it. Its not brain surgery.

I am in the process of removing the stock Flared heat shield and replacing it with a 6 inch straight aftermarket heat shield to get rid of that flared one. I will of course be posting that up with pictures as soon as it arrives. Should be early next week.

You might want to look at my pictures of the MAC on and thats so far with the stock heat shield. And in that thread... "Jardine ...now MAC" I talk about the install and the heat shield issue.

I will indeed post that replacement of the heat shield. At this point I just ordered the replacement today. And of course there is still the unknown about the fit that I cannot comment on until I get it and try it. So its all up in the air at this point.

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klx650sm2002 Serious Thumper Offline The more I learn the less I know. Posts: 2041 Cumbria,England Gender:	Re: Replacing Exhaust? Reply #3 - 12/02/04 at 03:19:24 Smoknweels, you have to re-jet even with a standard silencer. For advice on jetting see what red2k1 has to say on "Backfiring". Clive W
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Savage_Greg

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Don't go around your
ass to reach your
elbow...

Posts: 7844
SW Washington State
Gender: male

Re: Replacing Exhaust?
Reply #4 - 12/02/04 at 14:56:10

This sounds like another topic is needed in the Tech corner, but I don't know how to do it. Gandolf is asking a common question.

In this group, we have a blend of 4 exhaust options and we are all in general agreement that the carb requires rejetting, however there are 3 or so general opinions about how that should be done.

I happen to think that individual jet changes are the easiest and least expensive, but others feel more comfortable with the Dial-a-Jet, and still others think that removing the spacer and adjusting the idle mixture is all that's needed....

But I guess what really matters is the end result...no backfires and no blued pipes with more performance. Right? If it works, it is good....

How can we condense this for a Tech Corner subject of reference? Any ideas?

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Susan

Serious Thumper
2004 No Login

Offline

Been AWOL but I'm
back...

Posts: 682
Eastern PA
Gender: female

Re: Replacing Exhaust?
Reply #5 - 12/03/04 at 07:16:22

Savage_Greg wrote on 12/31/69 at 16:00:12:

This sounds like another topic is needed in the Tech corner, but I don't know how to do it. Gandolf is asking a common question.

In this group, we have a blend of 4 exhaust options and we are all in general agreement that the carb requires rejetting, however there are 3 or so general opinions about how that should be done.

I happen to think that individual jet changes are the easiest and least expensive, but others feel more comfortable with the Dial-a-Jet, and still others think that removing the spacer and adjusting the idle mixture is all that's needed....

But I guess what really matters is the end result...no backfires and no blued pipes with more performance. Right? If it works, it is good....

How can we condense this for a Tech Corner subject of reference? Any ideas?

I had said I was going to write it up but I am not sure I can. I have started a couple of times and gotten overwhelmed. There is so much info on all the various options and since I haven't done any of them myself I feel like I am in over my head.

Maybe instead what we need is someone who has done each of the various exhaust mods to write up a topic about it pros/cons etc.. and then I could create an overview topic that links to each of them. What do you think? Do we have any volunteers to write up their exhaust?

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Susan
Eastern PA
2004 Purple Savage

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cphilip

Ex Member

Re: Replacing Exhaust?
Reply #6 - 12/03/04 at 07:31:37

That sounds like a Greg 650 job to me! He at least has installed several of the types.

Many of it exists here in multiple threads. Perhaps a copy - paste overview complilation of them?

... or a merging of threads. I think you should have an option to merge threads Susan? That might end up rather confusing though as they normaly merge by post times and then they end up not making much sense. So thats not the best option.

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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Replacing Exhaust? Reply #7 - 12/04/04 at 13:45:49 If I have some extra time, I'll work on the SuperTrapp mod....with the jetting changes.
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Max_Morley

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LT650 Luxury Touring
& sidecar rig

Posts: 1490
Moses Lake. WA
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Re: Replacing Exhaust?
Reply #8 - 12/04/04 at 16:04:56

Well I'll shre what I have tried but wanted to make all of you aware of another options I learned about from Bert's site . got to www.performance-design.net. and see what they have. Supposed to have both low RPM torque and throttle response and high RPM HP in one. I first tried the HD sportster muffler, but found the one I had that came from Juneau AK was as heavy and restictive as the orginal one and blasted the rear brake lever mechanism. I punched a hole in the middle of the baffle and that seemed to help. I believe it may have been rusted so badly inside it wasn't very free flowing. Next was a super Trapp, worked OK and sound was much better. I stayed at 4 discs as the dealer had rejetted mine some for the previous owner and then me and ran rich enough with the white carb needle spacer in place. Next was a very noisy, but free flowing Hightway Hawk Drag pipe. too noisy for me. Managed to connect with a used RAASK drag pipe and used it for a new head pipe to an alleged HD Screamin Eagle pefromance muffler. Not sure if it is or isn't. Says 80 dbA on a HDFXD model and has HD script on one of the 2 mufflers in the set. Really like it as it is longer and carries the exhaust out to the end of my hard bags. I haven't modified the baffle in this HD muffler as I do not feel it is restrictive. It seemed to have bigger holes into and out of the glass packed part than the orginal sportster one I used. Also lighter. Would like to hear the performance design one as the poster on Bert's site is thinking 38-40 HP with the other mods he has made. air intake carb and cam. If so that is 20- 25% improvement and pretty good and out to make a real runner out of a Savage. Max

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Max at Thumper Acres. '96 Savage bagger, '03 Savage w/Cozy sidecar for wifeni.

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cphilip

Ex Member

heat shield picts up..
Reply #9 - 12/08/04 at 17:02:26

OK these are new picture links I just uploaded. First of all I appologize as they are just Phone cam ones for now and the muffler is not cleaned up after install. But I will get better ones up in a day or two. Just wanted to share so far as I am pretty pleased with the results...

These are after using a Cobra brand 6 " Universal Heat shield to replace the Flared out stock OEM one. While using the Mac muffler.

I got this today. Now this shows it on but yet not being cleaned up. I got lots of bluing discoloration under that old flared heat sheild. Ugly but not too suprising as I know it was not clean under there and all... Do not know if I can get all that off but a good bit came off later with just Mothers Mag polish. So I am hopefull. But I took the pictures before trying to clean the Blueing and the Black soot off.....I going to get some of that Bluego stuff and try and get some more off. Ugly now...

.... but as you can see... this heatshield works perfectly! I mean it looks stock now. Same shape and size as the forward OEM heatshield is as a matter of fact. Very good match to size and shape.

So... if I can clean her up... and so far have some... its going to be the perfect fit and fix for these conversions.

Cobra 99-0165P in 2" diameter. $16.99 at my local "stealer".

http://cphilip.mystarband.net/images/Newheatshield2.jpg

http://cphilip.mystarband.net/images/Newheatshield3.jpg

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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: Replacing Exhaust? Reply #10 - 12/09/04 at 05:15:47 Sweet! Just what I was looking for!
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cphilip

Ex Member

Re: Replacing Exhaust?
Reply #11 - 12/09/04 at 11:49:19

Ok I am having some decent success removing the blue and soot. Half of it came off with simple Mothers mag polish. Now I am using "Blue Away". If your not familiar with this stuff its pretty darn good. I am suprised. Its horridly expensive. A small bottle of it is like $14 but it does work. At least it seems to be working pretty good. I am now down to about 80 - 90% of it gone now with just hand application. Just with one or two applications and rubbing by hand. It was suggested to me to use a power buffer to really get it all off and I will indeed now go to that for the rest. But just testing it so far it is very encouraging. This stuff has a very fine pumis in it. Very fine particle but does not seem to scratch. At least not visibly. Surface is left very smooth and shiney. So far so good.

Now a word to the wise... most of mine came from not cleaning the hand prints off under the heat shield after installing the muffler. I did clean the main parts but did not wipe off the finger print oils and such before I installed the old Heat sheild back on. Thats where the problem is now. Under the old heat shield. As you can tell from the pictures. So a lot of my bluing is a result of that error. Should have done it... forgot to whipe it down before putting the heatshield back on ... and once I had it all together did clean the exposed areas before heating it up... but this area under the heatshiedl was no longer exposed to be cleaned anymore so it did not get properly "de-greased" as it should have. So it blued. You can even see the hand, palm and finger prints in it is where it blued the darkest. So be sure to wipe down that area with a solvent before reinstalling the heat shield. I used Alcohol on the rest of it and it did fine. This area should have been done too.

But I will give a review on this Blue Away product when I get the buffer out and finish up. But so far it seems to do the job. Not cheap... but does seem to be getting it done. I think the results are going to be satisfactory. But when I finaly get it done I will snap a picture. As you already can see the "before" in my previous pictures.

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Savage_Rob Serious Thumper Alliance Member Offline Mechanically Inclined Amateur Posts: 6972 Texas (Dallas area) Gender:	Re: Replacing Exhaust? Reply #12 - 12/09/04 at 13:08:38 You're blazing the trails for me on this... I'm not sure but I'd be willing to bet I cleaned up AFTER putting the heat shield on too. I'll probably be doing about the same thing soon. I did not find the Cobra shield in stock at any local dealers but one ordered it for me and it is supposed to arrive in a day or two.
Back to top	1998\|MAC muffler\|ceramic coated header\|K&N air filter\|Amal Mk2 carb\|Odyssey battery\|iridium plug\|NC windshield\|Dunlop 491s\|Superbrace\|EBC brake rotor\|12.5" Progressive shocks\|Kuryakyn ISO grips IP Logged

cphilip

Ex Member

Re: Replacing Exhaust?
Reply #13 - 12/09/04 at 13:53:16

Not because I want too Rob... just happenstance! Grin

Oh... by the way. Blue Away is sold online by Eastwood. And its a tiny bit cheaper there. If you can wait and the shipping is not too bad.... it's $12.59 there. But I suppose $13.99 was not too bad and I could get it quick and local and needed it right away. But if some of you are needing something from eastwood anyway it's something to consider.

Eastwood Blue Away link here

And yes. The Heatshield was not in stock at my dealer either. Hense the wait between last week and now till I could fit and post. Ordered last Friday (I think) and arrived and picked up yesterday afternoon. And there is a mistake on the price I paid. It was $16.95 plus tax not $16.99 as previously posted. No biggie.

Yea... I just didn't even think about the cleaning up behind there before I replaced the heat shield. Hind site... but... unfortunately too late to benefit you. But maybe some one else can benefit from our trailblazing eh?

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Savage_Rob

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Re: Replacing Exhaust?
Reply #14 - 12/09/04 at 14:05:39

I noticed the same heat shield for sale online from TNT Action Sports in Illinois for $14.41 (+S/H, of course) but figured that amounted to about the same and my dealer says only a day or two for delivery so I figure it never hurts to throw some business their way every so often if for no other reason than they will know your face later. I also noticed what appeared to be a nearly identical heat shield on JCWhitney. However, I don't know the quality of the chrome on their part and I know Cobra makes quality stuff, so I went with the Cobra.

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