OK guys, I'll readily admit to teetering on the brink of insanity here with what I am about to propose, but hear me out and then offer me your best suggestions!  

The MAC muffler is getting on my last nerve.  Simply put, it is too loud for me.  Although I love the sound as far as the deep rumble it gives off.  The sound at high end is leaving me with ringing in my ears and sometimes headaches out the wazoo.

Now, I know that the mods we all discuss, and that I have done myself, greatly open up the performance of the bike.  What I am toying with is putting the stock can back on the bike -- read, my insanity showing through.

I don't want to ride my bike with earplugs, that takes away from my overall joy of riding.  

Here is what I want to know.  It is a given that the stock can restricts the airflow.  No qualms there.  It is a given I'll lose some top end performance with the stock can.  It is also a given that as Suzuki ships this bike from the factory, it is set up for maximum efficiency.

So... these things considered and the knowns all accounted for, if I reinstall the stock can, what would be the optimal jetting/air filter setup for performance?  In other words, with what combination can I get the maximum performance from my stock muffler?

Currently, I am at 152.5 on main jet, 55 pilot jet with 1/2 spacer.

I plan on leaving the 1/2 spacer, and possibly the 55 pilot.  I am thinking the 152.5 main with the stock muffler will be too fat, but I have a 150 main jet in the toolbox.

So, my thoughts are...

Stock muffler
150 main jet
55 pilot jet
1/2 spacer
K&N filter

What do you think of this combination for the maximum I could possibly get from the stock muffler?  Or, is there a better combination?

I await your response, and yes, I already know I am insane for even considering this!  

That's not really an option I'm considering.  I originally bought a Sportster muff and didn't like the way it fit up.

The bike is either going to stay as it is (not likely), or going back to the stock muffler.  That's why I asked the question the way I did.

I want to know the optimal jetting that I can use with the stock muffler to get the most performance from a stock muffler.

Thanks, babbalou.  That pretty much gives me the information I was looking for.  I think tomorrow, the stock can is going back on, main jet going down to 150 and pilot going back down to 52.5.

The MAC was nice in a way, but I guess I wasn't as into the sound as I thought I would be.  Another thing, a good part of my riding is late at night, as in 11 PM going to work.  I really don't like making a racket going through town  when everybody else is trying to sleep.  I know I wouldn't appreciate it.

My biggest reason though is my hearing.  I've tired really quick of my ears ringing after being on the bike for a few hours.  Helmet, no helmet, doesn't matter as it still bugs the hell out of me, and if I gotta wear earplugs to deaden it then I might as well just drive the truck!

Yeah, I'll probably max out in the upper 80's for speed, but I can count on one hand the times I have had to run that speed and not even raise one finger!  Translated, I just don't have the need.

Forunately, traffic in the Louisville/Southern Indiana area is pretty darn well behaved on the interstates.  I can run from here to Indianapolis (120 miles) and run 70-75 and never feel like I'm about to get run over.  Guess I got the best of both worlds here!  8)

I do know it will be nice to hear myself think once again!!!

Well, I haven't changed anything yet.  I'm still mulling over my options at this point.  Don't know which direction for sure I will go, but still leaning toward back to semi-stock.

I did go and talk some serious turkey with the Suzuki dealer today on a two-tone blue C50.  That is one sweet bike!!!  I may be adding to the stable before long.

My Savage is very cold natured as well.

Well, I'm awaiting the arrival of the muffler connector gasket and then the stock system is going back on.  Did the rejetting tonight, backed down to a 150 main jet and back to the stock pilot jet.  Will be leaving the half spacer, and should be good to go.

I figure this should give me a few extra miles to the gallon, since the main purpose of the Savage for me is commuting.  Actually this decision just got made a bit easier since my family doc tells me I am now suffering from migraine headaches, so I won't have the noise to deal with now.

I wanted to try and strike a balance of performance/economy.  The bike didn't do bad on gas with all the mods.  I got around 52-54.  However, if I am going back stock, then I need to reduce some of the jetting or else I'll be way too rich.

I figure I may see a bump up to around 56-58 with this combination.

I would stick with the Mac, I know its kinda loud but that is why they call it the thumper.  Heck if u think that is loud try it without the baffle.  Now that is LOUD.

I wouldnt go back to the stock muffler because with that huge baffle it will hinder your preformance and sound like a sewing machine hehe.
Not to mention it looks like a propane tank hah.

I wonder if u could get some kind of packing materia that would would dampen the sound but not burn up and fly out the rear end of it.  Just a suggestion.