How to Modify a Stock Silencer??

canaberg · Dec 29, 2009

Gents!

I have been fishing for a used slip-on to get something freer breathing on the end of the pipe for our ice racer.

Not having tripped over anything along those lines yet, and with time to the start of the season becoming short, I am wondering.....has anyone messed with trying to open up the stock FE silencers?

This application is in an envrionment where a bit more noise is not going to pose a problem, although, I have no interest in making the thing harsh-loud as it would drive you nuts after a few hours in the saddle.

Rather, if it's possible to create a freer breathing can without making it a crazy amount louder, that would be nice.

Realizing that experimenting in the dark with mods like this might just as likely ruin the can, I am wondering if anyone has tried making the stock silencer a bit less of a cork at the end of the pipe?

Hoping there are some folks who may have tried this....or, may have some opinions on what they would change if trying to make the stocker flow easier.

VegasPlayer · Dec 29, 2009

You may want to send Tuts a PM. He modified the can on his FE650 and I believe he likes the results.

bushmechanic · Dec 29, 2009

I did this

http://www.husaberg.org/index.php?set_a ... _photo.php

its better than a slip on akra for bottom end and the delivery is much smoother, akra gained power above 7000rpm

F+ just cut a big hole in the stock endcap and removed the little pipe altogether I'd try that first

bowser · Dec 29, 2009

I modded my end cap as it felt like the muffler chocked the bike, I basically stripped the muffler and cut out the s bend and installed a short bit of pipe with a taper on the end to join the end cap's existing smaller diameter pipe.
see picture below.

it felt better riding but still felt chocked, noise was louder but not over the top at all. picked up a titanium FMF 4.1 for a good price so i chucked it on and bike no longer feels chocked up. Power is amazingly better and honestly the noise isn't as bad as i thought it would be. sure it's loud when you get up it but i wouldn't say it's over the top.

sickd · Dec 29, 2009

was the fmf pipe to suit a berg or are they the same as another bike?

bowser · Dec 29, 2009

sickd said:
was the fmf pipe to suit a berg or are they the same as another bike?

to suit the berg, check out the fmf website

F+ · Dec 30, 2009

This works for me, I still might cut more and add a screen. Yes, it's alittle loud.

awilksch · Dec 30, 2009

hey canaberg, bit of a coincidence that i just re packed my bro in laws FE550 silencer tonight, but anyway, i digress....

for $150A you can still pick up the prorider KTM endcap (see my gallery ' awilksch ' for pictures of my install), if you want to get one of these contact ORANGEBERG in australia, you ill find his details on this website, the design recently changed from a stock looking chrome end cone, to a milled alloy one, but the results are the same i believe.

the result was not far short of an akra slip on when i installed mine, I have an akra slip on now, yes its loud, but it is not obnoxious. it may be close to the F+ mod mentioned above power and noise wise, because it does open it all up a bit.

Azza.

tuts · Dec 30, 2009

VegasPlayer said:
You may want to send Tuts a PM. He modified the can on his FE650 and I believe he likes the results.

i must also add that he is an exceptionally smart guy whose knowledge is only surpassed by his kindness and pleasant demeanor.
he is a true asset to all who have ever had the pleasure of dealing with him.
it's sad, but words can't express the real tuts.
i know my life has been brightened by his wholesome goodness glow.

thanks vegasplayer, but let's try to focus on the issue at hand.
i don't want to, although i could easily, go on and on about myself.
let's just leave it at that i believe i am the most modest person that exists, including past, present, and future.

i did some surgery to the stock until which helped the performance and removed the dreaded turbine spark arrestor.
some basic tools are required and i moved one mount on both the frame [steel welding] and on the can itself [aluminum welding].
you could probably gut it without shortening it but i opted to shorten it because this is one of the few times i don't like a big 'can'.
i added an after market cap for the spark arrestor.
do you want/need more info?
tuts :devil:

sickd · Dec 30, 2009

tuts said:
VegasPlayer said:

You may want to send Tuts a PM. He modified the can on his FE650 and I believe he likes the results.

i must also add that he is an exceptionally smart guy whose knowledge is only surpassed by his kindness and pleasant demeanor.
he is a true asset to all who have ever had the pleasure of dealing with him.
it's sad, but words can't express the real tuts.
i know my life has been brightened by his wholesome goodness glow.

Click to expand...

thanks vegasplayer, but let's try to focus on the issue at hand.
i don't want to, although i could easily, go on and on about myself.
let's just leave it at that i believe i am the most modest person that exists, including past, present, and future.

i did some surgery to the stock until which helped the performance and removed the dreaded turbine spark arrestor.
some basic tools are required and i moved one mount on both the frame [steel welding] and on the can itself [aluminum welding].
you could probably gut it without shortening it but i opted to shorten it because this is one of the few times i don't like a big 'can'.
i added an after market cap for the spark arrestor.
do you want/need more info?
tuts :devil:

yes i would love some info on the whole mod you have done:
how much you shortened it
the internals you changed
the after market end cap you used etc
, could you take some pic of it aswell,
email is [email protected]

cheers mike

canaberg · Dec 30, 2009

Hey! Thanks to all for the replies. I got more info overnight that I could have hoped for.

- the pic of the mod F+ did is really great. That is likely to be my general template for that bit.
- feedback from mulitple sources that even just chucking the stock end cap is a big improvement
- more that the turbine spark arrester is evil and must die
- mostly you guys let me know that lots can be done with great results...equivalent or better than Akro in some ways

I am now unreasonably confident and will be going inside the can with nasty nipping and cutting tools. Gouging, ripping, drilling....bit of welding perhaps. I can hardly wait!

I'll leave the stock length and mounts, not feeling the need to tread into the more significant shortening work that Tuts did.

I will take before and after pictures to show the end result back here and report on power & noise once we get the big hummer rumbling. Do have another 650 available to steal a stock can from so we should be able to run it with both to feel the differences.

Thanks again to all & will feedback on the results!!

canaberg · Dec 30, 2009

canaberg said:
Hey! Thanks to all for the replies. I got more info overnight that I could have hoped for.

- the pic of the mod F+ did is really great. That is likely to be my general template for that bit.
- feedback from mulitple sources that even just chucking the stock end cap is a big improvement
- more that the turbine spark arrester is evil and must die
- mostly you guys let me know that lots can be done with great results...equivalent or better than Akro in some ways

I am now unreasonably confident and will be going inside the can with nasty nipping and cutting tools. Gouging, ripping, drilling....bit of welding perhaps. I can hardly wait!

I'll leave the stock length and mounts, not feeling the need to tread into the more significant shortening work that Tuts did.

I will take before and after pictures to show the end result back here and report on power & noise once we get the big hummer rumbling. Do have another 650 available to steal a stock can from so we should be able to run it with both to feel the differences.

Thanks again to all & will feedback on the results!!

Oops!

I meant the pic of bushmechanic's mod will likely be my template. My dead slow dial-up internet connection had not downloaded F+'s pics before I made my reply. I get confused easily! I like the pics from F+ too and will have both in mind when I dump out the innards.

Thanks!

fryguy · Dec 30, 2009

Canaberg...why do you want more power???

And Tuts, you are modest??...You never said much around me to make me think much more than you were a very shy introvert.

canaberg · Dec 30, 2009

Fry, Fry... Fry...... it's not that we want more power, it's just that potential for it is being made available via engines mods primarily intended to improve overall realiability.

There's this nice cam, see, that was born in the real world and designed with practical function in mind by the forces of good (a reference to someone named Lineweaver could be slid in here). Unlike the ridiculous, hour glass shaped stocker, born on the darkside and rendered by the forces of evil, that needs equally ridiculous and evil spring rates to keep the rockers following that hideous lump, the real world cam has a nice, normal round profile and allows normal valve spring rates dramatically reducing wear (and drag) on the whole cam/rocker arm/valve assembly.

In addition (this is the fun part), this stress friendly cam also does interesting things with lift/duration/timing that broaden power delivery and even bump output in the mid and upper rpm ranges....especially if you let the engine breath out the back end. Hence, having opted to use the cam for reliability purposes and overall engine longevity, it does seem silly not to take full advantage of the power bump it also offers by opening up the pipe to let the cam deliver all its benefits.

More power, better power profile (particularly for our purpose out on the ice), and the key bit.....with less engine stress and wear at the same time. How could we not want that?

Just gotta gut the silencer! :crazy:

We'll be the really fast, slightly noisy bike. Watch out when the fat, old guy is twisting the throttle. He forgets about the brakes sometimes...panic slides....hard on snowbanks.

....yes, we'll let you ride it. :shock:

fryguy · Dec 31, 2009

|Geez...if you put a cam in that thing, I'll be intimidated. I'd just rather look at your smiling face!!! I hope to make it out to the ice again this winter a couple times, hope to see you and Jesse rip it up.

Merry Crhistmas and happy hacking

fry

bushmechanic · Jan 1, 2010

is it an X1 or X2

canaberg · Jan 2, 2010

Took me a minute to figure out what the questoin meant since we did not actually deliberate over which cam. Just talked with Dale, explaining how we were using the motor, and are using his recommencation for our applicatoin.

Thinking back through our converstatoins, however, I believe I did hear him say, "X1"....but, I could be wrong.

:?:

bushmechanic · Jan 3, 2010

ah right I think it would be the X1 if you've been advised to use an open exhaust?

I'm running taffys tourque cam with my modified endcap, similar to the X2 I guess, its a lot smoother power delivery than the stock "08" cam, moved the peak power down in the revs and is more tolerant of throttle position at low rpm, valve train noise is nicer and the off idle tourque increased, the downside is its lost rpm and peak power is down a little. Madero said the same.

sounds good for engine longevity, less rpm, less peak power, smoother delivery. its a tad boring really but its faster from the off idle tourque increase, minimum corner speed is up.

the tourque cam or an x-2 with the akra might be good is where i was headed

be great to see what you think comparing your new cam to the stock one.

sickd · Feb 18, 2010

i have moded the end cap and opened exhaust up like bushmechanic done in his gallery, now do i have to change the carbi settings at all,
bushmechanic i am from victoria would you be able to et me know if my standard setting are ok?
not looking for super performance or anything just making sure i wont hurt the engine?

my factory settings are in this pic?

bushmechanic · Feb 19, 2010

dunno really, you gotta check whats really in the carb too right?

a #165 main air jet helped stop my bike going lean at high rpm

there is some info in the doc and steves thread "650fe so far" for aust input with an endcap mod at 800m, Is that right Steve?

also here http://www.factorypro.com/tech/carbkei.html

if you start mucking about with jets stick to one kind of fuel, where I live a #153 main on bp ultimate = a #160 main on caltex vortex 98

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