Tweet
How to make your stock muffler on your Katana sound like an aftermarket slip-on. I will give the steps I took to make my exhaust on my 2005 Katana sound great for Free.
Remember: I work on airplanes for a living. So I have access to all the tools I need and also an Air Compressor. This job took around 2 hours. And that was doing alot a experiment with what I had read from another post on how to do this and this method to the quickest and cleanest way to do it.
Tools needed (or that I used) : Saftey googles, gloves, breathing mask, A Rachet, 12mm socket, 12mm wrench, Needle nose pliers, Dremel (with alot of little cut-off wheels), 90 degree highspeed (w/ attaching parts the adapter to use sanding disc), 2" hole saw, rotary file, and some type of spray lube.
First: I removed the muffler from the bike.(Only 3 bolts all 12mm)
Next: I used the Dremel tool with a cut-off wheel attached and cut as low as I could into the smaller pipe at the outlet of the muffler.
Next: You should be low enough to use the 2" holesaw. Now insert the 2" holesaw into the outlet and cutout the metal plate that the smaller pipe to welded to. ( Tryed using a 1 3/4 holesaw it wont clear the weld. With the 2" holesaw I had to grind out the out pipe so it would fit, also spray some oil while cutting makes it easier.)
Next: Once the holesaw cut through metal plate remove the holesaw from the tube and use the dremel to cut the small pipe. I cutted about 1" past the metal plate. Then I was able to remove the plate and pipe with some needle nose pliers.
Next: Use the rotary file on a highspeed to grind the excess metal that 2" inch holesaw do not get. I grinded my then it was flush with the outpipe. (But not being to picky)
Next: I use an adapter for a 1 or 1 1/2 inch course sand disc on my 90 degree high speed and grind the smaller pipe smooth.
Last: I turn the exhaust upside down and blow out the metal shaving and install the pipe into the bike ( which is only 3 bolts)
The bike has a great sound. Real deep at idle. My friend as a muzzy on his 06 Ninja 636 and at idle we sound the same. But in high rpm his is louder. Now I was consider buying a hindle slip-on, but now I am thinking twice. The bike is perfect in sound to me I wanted something that was mildly loud, except when cruising around 70mph you can kinda hear it but you hear more wind noise then anything. I felt no difference in power. The bike as still running great. No other mods were needed.
Video and pics coming very soon. Let me load them up
Remember: I work on airplanes for a living. So I have access to all the tools I need and also an Air Compressor. This job took around 2 hours. And that was doing alot a experiment with what I had read from another post on how to do this and this method to the quickest and cleanest way to do it.
Tools needed (or that I used) : Saftey googles, gloves, breathing mask, A Rachet, 12mm socket, 12mm wrench, Needle nose pliers, Dremel (with alot of little cut-off wheels), 90 degree highspeed (w/ attaching parts the adapter to use sanding disc), 2" hole saw, rotary file, and some type of spray lube.
First: I removed the muffler from the bike.(Only 3 bolts all 12mm)
Next: I used the Dremel tool with a cut-off wheel attached and cut as low as I could into the smaller pipe at the outlet of the muffler.
Next: You should be low enough to use the 2" holesaw. Now insert the 2" holesaw into the outlet and cutout the metal plate that the smaller pipe to welded to. ( Tryed using a 1 3/4 holesaw it wont clear the weld. With the 2" holesaw I had to grind out the out pipe so it would fit, also spray some oil while cutting makes it easier.)
Next: Once the holesaw cut through metal plate remove the holesaw from the tube and use the dremel to cut the small pipe. I cutted about 1" past the metal plate. Then I was able to remove the plate and pipe with some needle nose pliers.
Next: Use the rotary file on a highspeed to grind the excess metal that 2" inch holesaw do not get. I grinded my then it was flush with the outpipe. (But not being to picky)
Next: I use an adapter for a 1 or 1 1/2 inch course sand disc on my 90 degree high speed and grind the smaller pipe smooth.
Last: I turn the exhaust upside down and blow out the metal shaving and install the pipe into the bike ( which is only 3 bolts)
The bike has a great sound. Real deep at idle. My friend as a muzzy on his 06 Ninja 636 and at idle we sound the same. But in high rpm his is louder. Now I was consider buying a hindle slip-on, but now I am thinking twice. The bike is perfect in sound to me I wanted something that was mildly loud, except when cruising around 70mph you can kinda hear it but you hear more wind noise then anything. I felt no difference in power. The bike as still running great. No other mods were needed.
Video and pics coming very soon. Let me load them up
Comment