hlwms2

Does anyone have a set of stock mufflers for a 2003 Volusia. Must be as new.
I will buy or I will trade a set that is totally debaffled or a drilled set that I have. Both are too loud for me.

I live in Chattanooga TN and would appreciate help in finding a set of quieter
exhaust.

hlwms2@me.com

id-man

hlwms2,
I recently modded my gutted pipes to something vastly quieter but still beefy sounding, and it only cost $32 shipped. What I did was insert a pair of these 3" x 13" glasspack mufflers into the gutted chambers.

Jones Exhaust A3012B - Jones Glasspack Mufflers - Overview - SummitRacing.com



Wow what a throaty, meaty but still quiet sound - I can not imagine any after market pipe suiting my ear better for any price. There is just one condition, the outside diameter is about 1/8" too fat to fit in the opening. The fix involves splitting the outside sheathing with a cutoff wheel and grinder motor. If you have that tool then it's a 5min per pipe install. Split the full length of the case, squeeze the sides together to make it skinnier, and slip into the pipe. I had to tap in the last inch and they are well snugged in there with no sign of loosening over two weeks since I did it. The sound is awesome, strong and muscular but refined, not ratty like the open pipes. In spite of being quiet is sounds tough...like a much larger more powerful motor that happens to have excellent mufflers. It's the best $32 I have spent on my bike.


Splitting the cases:
this was not pretty but it wasn't hard either, and the split is invisible inside the chamber, so go for it.

Here is approximately the line you want to cut:
An incision in the shape of a capital "I" down one length of the pipe.



One side was all I needed to split to make it fit...after it's cut tuck one lip under the other by squeezing with a vise or big channel locks. If it doesn't fit squeeze it some more till it does. By the time I was done mine went in loose all but the last inch which had to be tapped in (gently) with a block of wood. They're in really snug but if they ever start slipping I could add a setscrew. All in all a very easy install, much easier than removing old pipes and installing new ones...and the sound is tops, everybody compiments the new muscle:

Attached Images

	Glasspacks JEX-A3009B.jpg (12.0 KB, 1098 views)
	Glasspacks1.jpg (480.2 KB, 1106 views)
	Glasspacks2.jpg (537.6 KB, 1111 views)

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2006 C50T. Almost stock except for gutted pipes with glasspacks,
Homeboy seat pan mod, Cobra crash bars,
and NAPA 4416 running lights.

hlwms2

Thanks I may give this a try.

dwighop

If you're still looking and they fit. I've got my stock 2005 C50 exhaust. Really don't know about fitment.

__________________
Dwighop

JRJCCO

In case you are still looking - I have a complete, OEM, unmolested, stock exhaust system from an 04 Volusia that was swapped out for an aftermarket system when the bike was new. While I can't say 100% they'll fit - I'm pretty sure they should ! Let me know if you have any interest !