Remove end caps
The floor jack method of removal of exit nozzles.
End cap and mechanical baffle removed.
Cut around mechanical baffle with die grinder or air tool.
Drill around perimeter of CAT with 1/4" to 3/8" drill bit, make sure the bit is long enough.
Using a heavy bar to pound out CAT core after perimeter drilling.
Side shot of bar and intake nozzle assembly.
Fitting the new baffle over the CAT holder.
With the baffle fitted do a dry run assemble of the outer can and end pieces.
Once sized mark and drill out for two stainless steel rivets.
Reuse old bits of packing from stock pipe to fill in voids where the CAT holder cap is.
Refit out can making sure you have the right side up and the rivet holes line up.
Stuff with packing
Leave a bit of room at the top for end cap fitment.
Rivet it back to together and your done.
No shims just wide open performance.
It's best to remove the CAT side first and Push the exit nozzle of by pounding the inside of the mechanical baffle with a large rod or floor jack handle. The above pictures shows me pounding the exit nozzle off with a bar of aluminum. IT works but it's so much faster to knock them out from other side.
Simply pound the can up and down on the jack handle, it takes a bit of work but in about 4 or 5 minutes you will have the nozzle out and ready for cutting.
We used a piece of bent fork for the bar but a floor jack handle works equally well.
A good idea to clean up the remaining CAT bits still stuck to the sides. Use a long narrow chisle to remove these bits.
Make sure you have enough baffle sticking up to mate with the exit nozzle, the baffle will fit over the outside diameter of the inner exit nozzle. You'll understand when you see it.
Using a slendor tamping rod ours was made from a semi flattened peice of electrical conduit.It's important to work the packing around the baffle to avoid having voids or open spaces. This is SilentSport's packing. I have since switched to blanket style packing that you simply wrap around the core and fix with safty wire.
You can pack it full if you like but fitting the end can will be more difficult. This also helps you from over stuffing the can it will settle out some once you warm them up once or twice.
Stock to wide open performance in about 3 hours; less if you have experience.
Be sure you bike has map 5.0.2 uploaded, best if you have the airbox opened and better yet with PCIII usb and a custom dyno tune!
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Remove end caps
It's best to remove the CAT side first and Push the exit nozzle of by pounding the inside of the mechanical baffle with a large rod or floor jack handle. The above pictures shows me pounding the exit nozzle off with a bar of aluminum. IT works but it's so much faster to knock them out from other side.
