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Modify Exhaust from a Different Machine

by atvman29

You may have noticed that there aren't a lot of options when it comes to after-market exhausts for the 230, so in this article, I will try to explain how I made a Supertrapp IDS2 Quiet Series muffler originally off a Yamaha Warrior work for my Suzuki 230.  First thing you want to make sure of is that you're making a logical choice when selecting a muffler.  You want to pick one from a machine that is similar in cc's to the 230, so going larger than what I did with the 350cc Warrior pipe, would probably not be a good idea.  If you can find a nice pipe from a Honda 250X or something similar, that would be ideal.  Be careful not to get a 2-stroke muffler.

When you get your exhaust, evaluate what you have.  I had a complete stock exhaust system on my 230, and the Warrior pipe I picked up had the muffler and half the head pipe. Judging by what I had, I knew I had to use a good portion of the existing stock system.

The first step is to remove the rear plastics (if you don't know how to do that, you probably shouldn't be doing this!!) and disconnect the stock exhaust where the tail pipe and the head pipe meet.  Now bolt on the new muffler and see how it fits.  You may need to make some custom brackets to get it to mount correctly.  Try to get an idea of how you're going to need to modify the stock system to match up.

The muffler I got had a pipe coming out of the back of it that was shaped like a cone.  I also noticed that the stock exhaust had a cone right before the muffler.  I decided that I would try to get the two cones to connect to one another.  Finding where I wanted to make my cuts was the challenging part.  I held the stock system and the new system side by side being sure the mounting locations were in their respected positions and made marks where the diameters of the cones were the same and the new muffler would be able to utilize the correct mounting locations.  I used the rear, stock mounting position for mine, this way I could still use the muffler mounting bolt to bolt the grab bar.

You want to keep the diameters of the cones the same so that when you go to weld the two together, they'll butt up better.  Be sure to verify where you want to cut, and maybe even remount them to the vehicle and double check fitments.  Always measure twice, cut once!  Once you are sure of where you want to cut, make your cuts.  Be aware that the stock system has a drilled out pipe seen in the pics above, inside the cone.  Try not to cut into that when you're making your cut.  After you've cut, check and see that the diameters are the same and be sure that when you butt the two ends together, they fit together nice and flush so you don't have to weld across any huge gaps.  If you want to, you can cut off the drilled out tube, it all depends on the system you got.  As you can see in the pictures, the Supertrapp pipe has a screen on the back side, so I had to cut most of the drilled out tube off.  Then, mount the new setup on the vehicle to make sure everything will fit right one they're welded together.

Next, weld the parts together keeping the mounting orientation in mind and then you can mount it up to the vehicle and see how it fits!  Depending on the system you chose, you may need to adjust the jetting to ensure the vehicle is running at peak performance.  

I chose the Supertrapp pipe because it was a $350 dollar system that I got lightly used for $50, they have spark arrestors, and Supertrapps are adjustable.  They have discs inside the muffler that you can add or remove to change the vehicle's performance.  The more discs you have, the larger the exhaust outlet, which results in more power, and noise, or you can remove discs for decreased performance and less noise.  I believe mine has the 6-8 discs which Supertrapp recommends for stock engines.  The sounds levels are a little over stock, but it sounds SO much better (My system was the IDS2 Quiet Series, the Racing series is meant for closed courses)!  Check out the video in the Videos section of the gallery to hear what my 230 sounds like with the Supertrapp pipe!

If you want more info on Supertrapp Pipes, here's the link to their website: