I would just buy a aftermarket one.

 

You can cut the 90deg elbow off at the muffler side weld (engine side) to remove the cat you will need to drill a lot of holes into the honeycomb section and pull it out this takes a bit of time then re-weld the elbow back on
Prior to removing the elbow mark it in a few locations so you get it aligned properly again

 

You can cut the 90deg elbow off at the muffler side weld (engine side) to remove the cat you will need to drill a lot of holes into the honeycomb section and pull it out this takes a bit of time then re-weld the elbow back on
Prior to removing the elbow mark it in a few locations so you get it aligned properly again

No need to drill a bunch of holes. I used a hole saw the same inside diameter of the exhaust. Quick and easy.

 

I would never do such a thing, but if I did, I’d drill a bunch of holes in the cat with a 1/2” arbor bit then go at the remaining bits with a large chisel and dead blow hammer. If you’ve got a tig welder and correct filler, the job takes about an hour.

 

Easy to do... I did it when mine was new... Keeps it quiet and you can gain performance...and engine runs cooler...I run stage 3-4 tunes with the stock muffler with no cat

 

ya I gutted my stock exhaust. Cut off elbow. drill and chisel cat out, re weld. Pretty simple task. I also own the AA exhaust. but the more I rode with it, the more I didnt like the tone, and its just to damn loud for where I normally ride. When you mod the stock exhaust it let so much more heat escape its unreal, and ultimately thats what your trying to achieve with the AA exhaust anyways.

 

Exactly!!

 

What they all said , ecept some people will drill the inner holes , once the cat is removed to bigger diameter , don't do it it will sound ratty , also leave the spark arrester in , just make sure it's clean every few rides.

 

Does this Mod make the exhaust louder?
Does it sound any different?

 

My machine was so loud with aftermarket exhaust I learned to hate it. Going back to stock exhaust it is so quiet in comparison and really like the tone.

I did not check DB level before and after, but JMO- stock muffler is not louder minus cat and with flame arrestor.

 

I haven't proven my thoughts, but I really think my machine runs better 50-80 with stock exhaust minus cat compared to aftermarket exhaust. Running S3 clutch kit and AA stage 2 tune.

I also run flame arrestor. When I blew flame arrestor on aftermarket exhaust, I went back to stock exhaust minus cat and replaced flame arrestor. Did not make holes bigger downstream of cat. Really like sound of stock exhaust.

 

I do like the sound of the stock exhaust on all the turbo models. But I have one question. Is this done purely to help the system run slightly cooler? Or is there any other gain?

 

Gray:
The cat delete is well known and well respected. It will improve both throttle response and peak HP (on a turbo), and will have no significant sound signature affect. It is THE best upgrade for the dollar you can do (other than using good lubricants). The engine will also run a bit cooler, although not lots, for we're stuck with the 180 degree thermostat.

Eric:
I have a pretty complete post on aftermarket exhaust and HP implications, and if you want a lot of details I suggest you find it and read it over. However: The cat will rob peak HP, and the significant heat from the cat will both affect lag (which equals power at any point in time) and to some degree again peak HP. It's all about pressure differential at the turbo vanes.

There is, however, no reason to hunt the "how loud can it be" crowd. Most aftermarkets are simply too loud, although its possible to build them and make them quiet enough. I built mine, as an example. There is a full thread on that in the DIY section too.

 

On my XP1000 I cut the weld bead next to the muffler and the CAT came out whole. Same bead connected the elbow so that one cut was all that was needed. Turbo muffler looks the same.

 

I like this idea of no loose cat pieces floating around in the muffler. Any pictures of where you exactly cut?

 

This seam. I used a cutoff wheel down the middle of it. Also marked 4 lines to line up afterwards for rewelding like others stated.

 

😁Thanks all for the info and pics. As I stated, I want to 'look stock' and stay as quiet as possible. Trying to fool my riding posse for a while, anyhow! I did a similar mod on my T-Cat snowmobile (no cat converter, but some drilling freed up some ponies with just a little increase in noise) although I eventually did go with a muffler for more HP. The folks from AA just sent me the programmer with stock mod, stages 2, & 3 loaded, and clutching. Damn I wish the machine would get here! BTW, is this muffler made from stainless?

 

Not a clean stainless like 308 or 316 might be low carbon steel. Mine did have some surface rust. I painted it with high temp paint for now, may get it ceramic coated in the future if I stick with it.

 

If it's stainless, I'll have someone else weld it. I could buy the wire and gas for my spool gun, but to do one job it's not worth it. Looks like a straight forward way to free up some ponies and release excess heat! Thanks!

 

If one does this mod, do they need to have a tuner to compensate for anything?

 

Some say it gets too lean without a tuner to add more fuel. Removing back pressure and adding more flow could in theory create a more lean condition. At any rate the tuner just makes them stupid fun to drive so that upgrade stands on its own merit.

 

Is there a tuner that doesn't go crazy on adding power? Say something like the tuner I had to add to my motor cycle once I put on an aftermarket exhaust. It didn't add any power but more like electronically jetting the carb.
I would have thought that these machines would be able to figure out their fuel ratio electronically with all the sensors they have.

 

Mike @ Aftermarket Assassins has really good tunes for the XP PRO.

 

AA is the best one I have found. You can pick the amount of gain you want. Level 1 is basically stock power but with limits removed and throttle remaped for better response. It will just drive a lot better. Runs cooler also.

 

I would have to find someone locally willing to do the welding. Don’t own a welder and really don’t want to go out and buy one. Of course I will also have to wait until I have a machine sitting in my garage

 

Is this worth doing on a xp 1000?


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I would say yes, lets the engine breath better, and lets the heat get out more efficiently

 

They have been people that cooked their XP1000 muffler..... I did mine just for piece of mind.

 

Ok that was only step 1 now you need to drill the shit out of it and then pull out the remaining pieces it is not that easy what some people have done is to use a hole saw

 

I understand what you are saying and I appreciate the response.
But I was trying to pull it out as an assembly like mentioned previously in the thread.
Wishing I would have done the holesaw trick at this point before I have bent the crap out of that flange on the cat. I may try to bend it back and go that route because as of right now it won’t budge. I can also see insulation packing in the muffler and with the whole cat removed it seems from what I can see that packing may or could “float” around.

 

Sorry, mine was a XP 1000 not a turbo and slid out intact.

 

i still have my pro muffler laying in the garage... has 50 ish miles on it...

 

I wonder if it is the same as a 2019 Turbo s?
If so, What would you want for it? Shipping would probably be pricey. You can PM me too