Shhhhhhhhh, don't tell anyone.

Notice the corner of the sticker came turned up to make it easier to remove.

I took apart the muffler Ryca supplies. I believe it's an Emgo. Here's the baffle.





Not much to it. Perforated tube with a perforated disk about 2/3 of the way along, a bit of thin fiberglass matting held on with wire. Okay.

Emgos seem to have a reputation for sounding kind of tinny and harsh. Since it's not a large muffler, there isn't the volume for a deep tone, so I figured I could at least cut some of the metallic harshness by adding more packing.

I had some SilentSport packing left over from the other bike. It's meant to be poked into canister style mufflers, between the core and the outer wall, but a disk on the end of the Emgo baffle meant I had to try to wrap it around.



I don't have any stainless steel wire to tie the packing in place, so it was a test of manual dexterity to hold it and slide-tuck-slide-tuck-slide the thing back into the cone. There's a ring inside the cone that complicates the process. But I got 'er done.



Of course, if I want to be very antisocial, I can pull the baffle altogether.

Moto - I'm sure you know this, but your attention to detail is truely awesome. I am very excited to see how your bike turns out, and I have a feeling RYCA is going to want many pictures to help sell their product. Thanks for all the great pictures and progress steps.

Does anyone know if it's okay to grind down this spot weld smack in the mouth of the exhaust pipe?



Or is it precisely engineered air flow optimizer?  

At least the muffler is simple enough to rework in various ways, if necessary.

I imagine the handle on the crumb catcher generates a scavenging vortex for an added 10hp.