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Discussion Starter #1
...because it was already junk. I just wanted to see how bad it was. On to the pictures..

Cleaning the paint off the welded areas:
http://imageshack.us/a/img716/8599/img08161o.jpg

Cutting all the way around:
http://imageshack.us/a/img16/2682/img08181.jpg

Pulling that sucker apart***:
http://imageshack.us/a/img59/9654/img08191.jpg

***You can't actually pull it apart, it only comes out this far. So I decided to cut the neck off to see what falls out. It sounded like there was a couple dozen nuts and bolts mixing around.

Cut the neck, find that the inner pipe had shattered and dropped into the middle chamber:
http://imageshack.us/a/img818/16/img08201d.jpg

http://imageshack.us/a/img13/2609/img08221h.jpg

Time to start looking for a new exhaust...suggestions??
 

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I realize you live in Mass. and it's pretty chilly up there right now, but I still would have done it the other way around - Found a new exhaust before I cut up the old one.
With that said, aftermarket exhausts for these things run along the lines of $450+ (sorry, I don't have access to too many references right now). I think I would do my best to find a used one (most likely will have similar issues) before buying something aftermarket. I suppose if you just have a bunch of money burning a hole in your pocket, go ahead and get a new one. It's probably your best, although most expensive, option.
 

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Discussion Starter #3
It's not that I have money burning a hole in pocket (with exception of the Amex card), but I also haven't ridden it in almost a year since I got my other bike (FZ1) so I figured it was time to take care of some maintenance items (routed the throttle cables wrong when replacing parking brake cable). The internals of the muffler were so bad it sounded like a small Harley going down the street
 

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malbojah said:
It's not that I have money burning a hole in pocket (with exception of the Amex card), but I also haven't ridden it in almost a year since I got my other bike (FZ1) so I figured it was time to take care of some maintenance items (routed the throttle cables wrong when replacing parking brake cable). The internals of the muffler were so bad it sounded like a small Harley going down the street
Hahahahahahahahahahahahahahahahahahahahahahahaha..A VERY SMALL HARLEY................ :lol: :lol:
 

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Mine fell apart internally is a different manner, it was rattling when I got the 'scoot with 12.3 k miles on it. There was zero, zilch, nada penetration on a couple of welds on the main tube support bracket--very poor welding:







I got a replacement from a 2005 model (eBay, $125 w/ shipping, 6800 miles claimed the seller) that remains fine 20k later...
 

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At about 20K, i noticed what sounded like an exhaust leak from my muffler. Now, at almost 24K, the exhaust noise sounds really mellow and rich. Only thing is, when I go over a speed bump, it sounds like I have a couple of pounds of broken glass inside the muffler. To replace it with a new one for $400+; I'll live with the occasional glass sound.
 

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I See there is no Packing like After Market Exhaust, Just Metal on Metal.

elliott,
 
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