I love the look of the standard exhaust tailpipe and also have yamaha luggage fitted, until recent threads on here I was going to put some cans on it but now I fear for my luggage, I know an exhaust fabricator so I think I will get him to rip mine apart, remove the cat and put in some nice baffle tubes with maybe a couple of decibel killers as well just in case, anything I need to know before I start the ball rolling, size of baffle pipe etc

Pretty straight forward to do yourself if you can weld it all back up afterwards.

Anyhow, almost all of what you need to know can be found here...

http://www.xt660.com/showthread.php?t=13652

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i write about it in my review but here it is in pics

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check out www.redbikejohn.com for all the latest race reports from the CHEC and enduroland.

Thanks guys, that's great. I would like to put in New baffle pipes and open up the outlets so they can poke through and maybe connect them up to the original inlet with like a 'y' piece or something, so you end up with straight through pipes rather than a box with holes in it, I would also wrap the baffle pipes with waddling and secure with wire before welding it all back up. What do you think?

Sounds like a lot of work. It works quite well when the extra holes are drilled and is just on the limit of ' not too loud '....

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check out www.redbikejohn.com for all the latest race reports from the CHEC and enduroland.

Thank for the cut open pics redbikejohn
Cannot believe the size & weight of the standard muffler, it'd be at home on a little hatchback car
Now I can see what's in store before I fire up the grinder with a "thin cut off wheel".
I intend to a use standard 2010-11 YZ450 slip on, (sourced at a swap meet over the weekend for $40) modified by shortening 100mm in length & laying over at an angle, trimming the original LHS XTZ heat shield & enlarging the outlet part. The end of the YZ pipe will be rotated from it's original position to suit the heat shield.

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Two wheels keeps you young. Regards. Russ

Sounds good. Straight through enduro/mx pipe will bark though!

I sourced a xt600 std pipe on eBay for �1 (!) and while its heavy in std trim I think it'll make a nice single pipe. Need to source a link pipe (might cut my on modified z pipe up) and I also need to gut the insides to lighten and and flow.

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check out www.redbikejohn.com for all the latest race reports from the CHEC and enduroland.

In the disassembly procedure today, I slipped the new muffler on & yes it is a bit loud but no more than the "Staintune pipe" on my old DR650
Anything is better than the abysmal stock tone. Sounds like a Lambretta a mates sister had in the early 70's

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Two wheels keeps you young. Regards. Russ

After some discussion with my enduro riding/ bike salesman son, I've decided against cutting 100mm of the YZ silencer. (Power & noise issues I'm told)
We sat down with all the parts, holding them in various positions, with panniers on & off to determine manufacture of various brackettry etc.
The current plan is, to mount the silencer first & then modify or build a new pipe (stainless of course) between the end of the header pipe & YZ silencer.
Attaching to the main mounting bracket, the one with two rubber mounts under seat, will a have cut down piece of 50mm x 25mm RHS (one 25mm side taken off) & a piece of flat welded in the end, where the mounting bolt should be located. (Pictures once it's all built prior to assembly).
All this started with building some pannier brackets for the DR

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Two wheels keeps you young. Regards. Russ

Looking fwd to seeing some pics of this bad mama jama