Exhaust options for 2009 SM510?

I was considering getting a power commander v and was curious how much I will be limited by the stock cans. Is it worth it to remove the cat? What is the sound like after removing the cat? Still streetable?

I figured I'd update this post since I decided to gut the stock cans. I was quoted 1100 bucks for the titanium slipons from my dealer. The full system is 1400 from motostrano so I figured the slipons would be a little cheaper then that. I decided to see how well gutting the stock cans works before buying anything.


Knocked the baffle out



The enemies

I am selling the stock can off my 09 TE, I also have a easy to slip in quiet core insert for those longer rides. PM me if intereted.

So how'd it work out? How's it sound? Do you recommend doing it?
Were you able to get the stock cans back together ok?

The stock cans haven't been welded back together yet. If you just want to remove the catalytic converter you don't have to do as much work.

Just drill the rivets and cut the weld like this:

The catalytic converter is wedged inside the inlet pipe. Then it is welded on the outside


The endcap and baffle probably impede flow as much or more than the catalytic converter. So it probably isn't worth just removing the cat. It is a lot of work to disassemble everything and then weld it all back up properly. I'll shoot a video of it when I'm done with it.

is everything in the vice pic going in the trash??
i thot about something like that but i'm sure it would be loud as all getout

Ok, thanks for the follow up. Looking forward to the video.

i did this as well! but i did it a little different and a little easier! i took the exhaust apart and used a saw-saw to cut apart the guts. seperating the cat piece from the rest of it! then i baught two 2ft long peices of 2 1/8OD exhaust pipe from autozone, and two 2 1/8inner diameter couplers. i measure 11 1/4inches from the cat to the beginning of the end cap. i mounted the coupler and 11inch peice to the cat and reassymbled the whole muffler with rivets. it was a tight fit but worked great! it's just a stright pipe from the cat to the end cap, all conceled by the stock exhaust outer shell! its really really loud though. but much easier then trying to weld the exhaust back together!
it also save a bunch of wait! i'll try to get pics of it!

hey mike thats what i was thinking about. but i was gonna use perforated tubing and pack it with fiberglas i guess to try to keep the noise down, but just using the outer shell like it sounds like u did

o ya, i was doing it mostly to cut down on the weight

johosjokers: No, the I'm going to reuse everything inside that can except the baffle. I'm also using the inner can with the perforated tube with the baffle removed. I don't know how well you will be able to seal that thing without using the inner can. That's why I'm using it. I don't want a big mess of fiberglass shooting everywhere.

mikezx: Thats an easier way of doing it but it doesn't seem like it does anything in the way of reducing exhaust noise. BTW did you tune the ECU at all? The mechanic at my dealer said they thing will run badly after the backpressure is changed so dramatically.

My plan is to finish the other pipe today and weld it all back up tomorrow so my bike will running again. I'll post some more pictures of the dissassembly so you guys know how I'm doing it. Anyone know what the cheapest place to get the PCV and Autotune?

I'm also considering cutting the pipe about 3 inches to give a cleaner look. Like right past the mounting bracket. What do you guys think?

No i havent had it tuned sence the exhaust mod, it runs fine but i can tell its running on the lean side. im buying the PCV and tuning kit next week from scott at semcodesigns. that should fix the running lean. and ya it doesn't reduce the noise at all its extremely loud. but i got some ideas on how to mess with the exhaust note after ive got the PCV. no hurry for me i got my break in mileage and now it's time time spec-up the bike with all the afermaket mods! let me know how it goes with reusing the stock muffler guts!

hey if you can get a clean nice cut on the muffler shell then go for it! i personally like the look of my exhaust the way it is! that and i dont want to risk screwing up my pipes! but ive read other post of people doing that to save wieght!

shorty cans might look great, if u do it give us the pics !

i may be taking my cans to work monday, i see some rivets getting drilled out in the near future

I did this same thing......but i also hole sawed the little 3/4 inch outlet tubing and replaced it with 1 5/8 stainless header tubing. It sounds like crapola (high pitched) if you dont modify that tiny outlet hole.

I was planning on doing that as well. If you look in the pics above you can see I took that pipe out of the end so I can open the end to match the tip. I have also decided that I'm not going to resize the perforated tube. I looked at a bunch of silencers and the perforated tube is generally about the same size of the inlet/outlet pipe. I guess I'll have to put more packing in to fill up the space.

Alright I finished the pipes check them out. I decided to make them shorty pipes to save weight. I used a little different method then listed above. I didn't reuse the innercan or the endpiece. I tightened the original perforated tube to the same diameter of the inlet pipe and put it right into the endcap. Its sealed up with rtv as you can see I haven't cleaned it all off yet. I'm planning to polish the aluminum cover to match the endcap.

is it way louder now?

Yeah it is loud and really deep. ill post a video tomorrow