Intruder 800 OEM Exhaust Modification:
The Intruder OEM exhaust system can be modified to obtain a louder sound by drilling holes in the rear plates of the exhaust baffle system. The OEM exhaust has a total of three plates. The first two can be drilled without adversely effecting performance. I recommend, however, that you drill only the outermost plate to see how you like the sound, then make your decision to drill the second plate based on sound and performance concerns.
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Locate the three rivets in the endcap of the exhaust system. Measure and drill three pilot holes that are equally spaced between the rivets as shown in the picture above. After drilling the pilot holes, drill the holes with a 1/2" drill bit. The metal is very hard, and will take some patience and care to drill without gouging up the plate. When drilling is complete, you can use a dremel tool to smooth out the rough edges. Finish the job by painting the rear plate with some flat black high-temperature paint.
If a louder sound is desired, drill through to the second plate, located inside the exhaust system. Be extremely careful doing this, because the glasspack inside the exhaust will be in the way. If you know you are going to drill through to the second layer, you may want to drill the outer plate holes a little farther towards the outer edge than I did in my modification, shown above. When drilling the second plate, it is recommended to use a 3/8" drill bit for that hole.
Disclaimer: The motorcycle owner assumes full responsibility for doing this modification, and safety of tools used. This is only a suggested modification, and is not warranted to be free from defect. Any damage caused to machinery or injury to personnel is solely the responsibility of the individual.
