[e1_ZX-9r]

I'll start off showing the result. I started with a 2002 ZX-9r. The mid-pipe outlet is 2 3/8" OD. I purchased a SuperTrapp muffler with a 2 1/2" ID, so the fit was a little loose.

The first stop was to Autozone for a 4" length 2 1/2" OD x 2 1/2" ID muffler sleeve and Permatex 101BR Ultra Copper silicone gasket. I cut the sleeve ID off, keeping the remaining ~1 13/16" length OD cone (see below). Next I made two length cuts to that, taking out about 1/4" (a single cut would have worked as well), turning the cone into a "C" shaped sleeve. A metal file was used to smooth out any rough edges on the muffler internals, sleeve, and mid-pipe outlet.

Everything is ready for a snug assembly. Just need to take it down for the rear set bracket TIG welds. Permatex will be used during final assembly to seal any air gaps between the three pieces. Let dry for several hours.

Step 1 of 10
Unbolt chrome beauty ring and make cut right at the mid-pipe exit weld.

Step 2 of 10
Not all hack saw cuts end up straight. I had to try about four different angles.

Step 3 of 10

Step 4 of 10

Step 5 of 10

Step 6 of 10
I removed the burrs with the sleeve away from the bike. This picture is just an example of the tools and angles used.

Step 7 of 10

Step 8 of 10

Step 9 of 10

Step 10 of 10

​

Drill muffler retainer pin hole, slide over the end clamp and tighten.

 

[BigRuss]

good thread

 

[JBear]

How's that sound? I've seen SuperTrapp muff's on a custom cruiser once, but this is the first (and second? LOL) time I've seen one on a sport bike.

 

[zaneyzrex]

did the same to fit the small akro meg to my zrx but why such a big section cut out ? gonna be a bitch to keep that big gap sealed with just RTV ....

 

[e1_ZX-9r]

Sound? A bit deafening at 9 diffuser discs, both from a rider's standpoint and from others riding with me, but civil enough that LEOs don't take notice. Everyone seems to love the roar made when I pass people (7K-12K RPM). They say it sounds like I'm really pissed.

For street use, I use a closed cap. For racing applications SuperTrapp makes an open end cap. They also make universal enclosed diffuser disc stainless steel mufflers that resemble something similar to a Muzzy.



Zan. You're exactly right. I goofed by cutting out a wedge. A simple straight cut would have sufficed or even a half-way cut, enough to get it to slip onto the mid-pipe. It was my estimation that I needed to remove some sleeve metal to get the two pieces to fit. I'm not concerned about the gap. I have some ideas about what to slip in there to help the Permatex seal.

 

[e1_ZX-9r]

$30 was the cost for the TIG weld, same as last time. Same crusty old welder guy too. Me riding the 2002 9R into a weld shop brought the place to a standstill. Oooo, check it out! How fast is it? What year? How big? Blah, blah, blah. Typical stuff, except for the questions about the SuperTrapp, which apparently most had not seen before and drew quizzical looks; adjustable? WHAT?! :headscratch Whoa, how does the exhaust get out?

My 2000 E1 was quicker until today.

A changing of the guard is kinda bumming me out.

2002 ZX-9R F1 showing TIG bracket welds.