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If it is a stock muffler then buy another stock muffler and put it on - they are ALL the same. Buell never changed the exhaust on the blast at all. If it is aftermarket(vance and hines) than you need to measure the pipe and find something that fits.
1. vacuum leaks at the back side of the carb spigots or other vacuum lines off/broken. Remove the carbs and spigots from the head and clean with acetone/laquer thinner afterward sealing the spigots to the head with gasket maker/silicone rtv. 2. Carb idle and low speed jets may be plugged up and carbs need a correct cleaning. 3. Carbs need rejetting to match the after market mufflers. Take it to a shop with a motorcycle chassis dyno and they will be able to tune the after market pipes.
As long as you get a muffler that is comparable to a stock muffler then it will have no effect on the performance. Most aftermarket companies make stock mufflers that would fit your bike though it would likely be cheaper to just replace them with stock kawasaki pipes. As to replacing them, using an impact wrench will make removal easier and be sure to use a new clamp even if the old one looks good
Honda mufflers typically have several baffle walls You may need a drill 14 or more inches in length to punch through enough of these walls to make a noticeable difference. Changing the back pressure of the exhaust will also lean the mixture. This may cause a bad hesitation on take off. This will happen if you change the exhaust system also. To correct the hesitation you may need to install a jet kit on a carburetor model (about $100) or install a Power Commander on a fuel injected model (about $400 plus programming). In both cases your fuel economy will go down. Your stock system has a five year warranty, should not blue like an aftermarket pipe (unless you leave the choke on too long), and have a good long service life. Unfortunately there is no easy solution for your problem. Any aftermarket system will be way to loud (especially on the freeway) and drilling may not give you the desired sound you are looking for leaving you angry and frustrated. Consider a different option, One of the best sound options I have heard was a set of stock Harley pipes adapted to a Yamaha Virago 1100. Most Harley riders change out there exhaust systems before they even ride there bikes which should offer a cheap high quality system that can be adapted to your stock headers with common automotive adapter pipes and custom build it yourself supports (a simple modification of your stock pipe support/mounts). By not damaging your stock system you can always put it back on if you do not get the desired effect.
It won't cause any engine problem, however it could get caught up where the exhaust exits the muffler thus causing a momentary power loss, the stock pipes are quite expensive you might be better going that route, you would have to cut the pipe open and then reweld it, that would be a lot of work, you are better off replacing it with either a stock one or aftermarket.
Try Steve's Cycle Salvage located in Tifton , Georgia.
http://www.stevescyclesalvage.com/ Call him on the phone as he says he's usually too busy to mess with e-mail. But, you can try it if you wish. Good Luck on finding your parts.
You didn't say if the new exhaust was the factory stock unit for your bike or an aftermarket pipe. The aftermarket pipes are generally not well manufactured. The factory pipes are well made but even they have internal flaws at times.
The flow of exhaust gasses is being held back by the baffles in the muffler. Some mufflers have an end baffle that can be removed from the end of the pipe. If one is present, remove it. This may help. Aside from that, return the new pipe and ask for a refund or replacement.
Most aftermarket exhaust systems are cat-back. You defiantly need to keep the cat to comply with local emsisions regualtions. However you can remove the mufflers and replace them with high flow mufflers or resonators. Try to replace them with something not too loud so you are in accordance with noise laws in your area. I have a 2000 s10 with no mufflers, just a cat then a y-pipe to make it dual with two resonators coming straight out the back, I live in the states and made sure this sytem was 50 state street legal before I purchased it. I suggest you do the same to avoid harrasment by the police.
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