supertrapp ids2 exhaust problems

[JSherlockHolmes@aol.com]

Hi Folks, Got a few confusing problems here that I hope someone can help out with. I just purchased the SuperTrapp IDS2 muffler for the KLR 650. (Part #611-6600). Unfortunately, the instructions don't appear to make sense in many places and I am fairly mechanically inclined. Am hoping someone who has experienced this before can shed some light for me. 1) Item #1 under "Installation" tells you to install the "S-bend" pipe to the head pipe using the stock gasket and the supplied T-bolt clamp. Sorry......the graphite/zinc heat gasket that joins the stock muffler to the head pipe will not fit into the "S-bend" pipe supplied by S-trapp. There is no way that circular gasket will fit in there, there is barely enough room to get the "S-bend" pipe to slide on the head pipe in the first place. What gives? 2) Item #2 under "Installation" tells you to rotate the "S-bend" until the Standoff lines up with the frame mounting point, and then install the aluminum spacer, washer, and bolt. What standoff? There isn't anything attached to the "S-bend" pipe. It is a smooth pipe bent in a couple different places. There is no "standoff" here. To make matters worse, Item #4 under "Installation" tells you to install the stock bolt, from hardware kit, into the muffler mount and tighten finger tight. Which one is it, it can't possibly be both? I think I figured out that the supplied spacer should be used between the aluminum muffler housing and the stock muffler mounting hole to locate the muffler and keep it from contacting the rear fender plastic. However, I am not sure how to solve the situation in #1 other than to apply some high temp silicone and hope it holds a good seal. Should I try one of those shrink fit exhaust pipe sleeves to go over the joint, under the clamp? What is the scoop? Oh, one more question for those in the know....... I am currently running a K&N carburetor re-calibration kit. I am using the DJ140 main jet, with the supplied needle set on groove #3, and my mixture screw is turned 3 1/2 turns out. I am also using a K&N air filter in the stock airbox. Can someone tell me what would be the best quantity of discs to run in my Supertrapp for best all-around performance? (I live in Milwaukee) Also, are there any recommendations on how many air filter box vents I should install for the best breathability of the intake system? Also, if anyone needs them....I now have one stock exhaust muffler with less than 3000 miles on it, a brand new stock seat, and two slightly used stock hand guards that I would be interested in selling for a very decent price. If anyone needs them, that is. Thanks alot, Jim Sherlock 97' KLR650, 82' FT500