Do you mean the red arrow welding?

http://img.photobucket.com/albums/v2...r/exhaust5.jpg

That's the point that I've cut. I think that there's another welding point somewhere. Maybe that piece is an expander welded from inside too. O_o

We have a different muffler... but to show you where I cut the old muffler. Take a look at this:

http://upload3.postimage.org/64630/gz003_muffler.jpg

Legends:
* green area is the stock muffler
* red area is the pipe and up to where it is extended into
* blue line is where I cut the original muffler (again, I did not cut "through" the pipe... just the muffler so the pipe or red area still extends to the partial overlapped green area).

Hope this helps. Sorry if I don't make much sense in my explanations... (not a mechanic myself) :-)

Thanks, John! The picture is quite clarifying. :tup:

My bike's muffler is something different, but today I'm going to cut the blue arrow welding. I'm sure that it's the way to go.

I've finally swaped mine. It has a tiny "red area" so it was hardly fixed there. I've needed the -free- help of a local workshop. :blush:

http://img.photobucket.com/albums/v2...racker/alc.jpg
Stock muffler.

Here's a video.

Now the mixture is quite lean again and I can't go further than 75 mph.
I'll carb the bike soon. :tup:

nice! i like the new pipe you put there. That stock muffler has a lot of baffles... I would assume that it is really quiet before.

congrats with the mod!

Hey. That looks like the internals of a catalytic converter. The Euro bikes don't have smog protection, do they?

Well, the stock exhaust wasn't noisy, but not really quite at all.

About that grid, sure that looks like a catalytic converter, but a carburetted bike shouldn't have one... Maybe is there to acomplish Euro-2 specs. :??:

Re: Muffler Swap
 

Jamie,
How is the bike running with the new muffler and the jetted carb? Have you made any recent changes that you'd like to share? I will take on this project this spring and have found everyone's input very helpful and interesting.

Re: Muffler Swap
 

I am thinking of doing the exhaust on my gz250.

here is my question: There are two pipes that are joined together under the heat shield, has any one considered putting dual exhaust on their bike or is this a bad idea? and if it is a bad idea why? :??:

Re: Muffler Swap
 

Not a bad idea if you like to spend money needlessly. A single cylinder 4 valve head doesn't need separate exhaust systems for each exhaust port. The GZ works well as is, why take a chance on fouling up it's ability to make reasonable power and compromising it dependability.