Jardine Job




		I drilled out my muffler a while back for better sound. See what I did here. It did a minimal job and still didn't give me the sound I was looking for. I stumbled across a used Jardine for a good deal and jumped on it. Don't buy used if you can avoid it--I didn't have all the parts and it has marks that I would have avoided getting on it. My advice: don't put it off, buy the Jardine! You will be so happy with the sound and appearance.

	I bought the Jardine used without any hardware. I bought the original muffler attachment parts (copper ring & clamp: $30!) thinking that I would do the job right.
	Just check out the difference in size and attractiveness. That original is damn huge!
	Sliding the compressible copper ring spacer on was a treat, as I had to sand the header pipe smooth enough to muscle on the ring.
	I needed to get the muffler opening as far as the screw driver is positioned, but the ring was too thick and would not go inside the circumference of the opening beyond the slotted part. I was getting impatient by this point.
	I used a hose clamp to try to "smush" the copper thinner. As smart as the idea was, it didn't work. I ended up removing the copper covering and inside is several layers of metal. I used a couple layers to close the gap and used my new muffler clamp. Waste of time and effort. The pieces ended up loosening up and doing absolutely nothing.
	*Update:* DON'T USE THIS JUNK, IT MELTED, DISINTEGRATED, AND BLEW ALL OVER MY HEADER PIPE!
expander tool	I bought a new copper ring to start all over. I tried heating the muffler end to expand the metal so it would slide over the copper ring. Didn't open enough, but some. After screwing around for an hour with my dad. I finally went to a muffler shop where a guy opened it up a little bit on a special pipe expander tool. No charge. He then told me I could borrow one for FREE from Auto Zone. He was right. I didn't end up needing to use the tool because it slid right on when I got home. I tightened the clamp and it sealed almost perfectly. I get a little bubbling of soapy water from the bottom of the connection. Not sure what to do about that just yet, clamp is tight as I can get it.
	Well, I finally got it on and damn did it look and sound great! I'll be looking for a small heat shield to cover up the joint, since it's ugly.
	The bike looks so different when you remove that "Propane tank" original muffler. Besides, what a sound!
	RE-JET INFO: I change main jet to #150 based on buddy recommendation. It screws in really easy and only cost $3 at the Suzuki dealer. This gives me more mid-range power and hopefully will prevent some of the discoloration I can expect to get with this Jardine. The bike has much better pick-up mid to full throttle, especially noticable in the 4th & 5th gears. I removed the battery box (4 bolts at bottom) to get access to the rear float bowl screws to get access to the main jet. I'm getting a slight pop on throttle close, but since the spark plug looks good and tan after a few hundred miles, and I'm thrilled with the performance, I'm leaving the carb alone!
To Do List: Fix tiny tiny leak at bottom of new joint: *Update:* I stopped the leak with Permax RTV silicone gasket maker from Auto Zone. There are several tubes, buy the red one, #26B Buy Heat shield?


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