Big Gun Exhaust
 
I do not like open exhaust thumpers, so I was glad to find that Big Gun makes a quiet core exhaust for this bike. Factory Pro tuning has tested some of their models and have found them to make good power with lower noise than the competition. I ordered up a full system from Cycle Tech in Ohio at a good discount ($450 included shipping). It didn't make a bunch more power, but it has a nice bark to it and a sharp throttle response, and it must weigh ten pounds less than that stock can (I'm not kidding!) You can insert the race core for track days too, and reportedly unbrazing a shield off the front of the quiet baffle gives a lot more power at a noise level somewhere in between. It may also increase your packing life, which is reportedly quite low because of the heat that builds up with the quiet core.
After two hundred miles, I reluctantly returned the Big Gun when I noticed the headpipe was firmly pressed onto the frame. I tried loosening and realigning everything a few times (no small task with this exhaust) and I could not fix this. In fact, its got very little clearance between headpipes, between collector and cylinder, and the headpipe also touches a water hose. In short, its just too tight. I talked to Big Gun and they believe KTM tolerances are to blame, but I know two others with this exhaust and they also had the same fitment issues. Reluctantly, I returned the exhaust. I almost kept it anyway, placing a rubber washer between the frame and exhaust, but I noticed that the mild steel pipes were starting to rust already at the spring hooks, y-collector and of course where the frame rubbed, so I gave up on them. I still think they are on the right track, but I'd prefer to see stainless and aluminum and MORE CLEARANCE! The fit was quite leaky too even with RTV silicone, but that's a price I think you pay for lightweight fitment and I could live with that.

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