Hi I will try and post with pics, this could take some time ...

So my bike is a ktm 690 enduro 2014, I did this to lose some of the heat ( which it has in my opinion) as for a weight saving by buying a akro $$ ££ well I weight 86 kilos and could do with losing a couple of kg's, so this will please the wife and doc

right here we go take one exhaust, I guess anybody doing this can take it off the bike (pretty simple process)


you will cut around the end weld.

I took my exhaust to my local welder to check that he could weld stainless and to get a price. he said yes and put some money in the tea/biscuit fund ( I put in £10) he also gave me a 1mm metal cutting disc, but these are a couple of £ from a hardware store.

Next cut carefully around the weld ( I guess you could use a hacksaw,but it won't be neat) and don't go to deep, then pull apart the pieces

here is the offending cat I drilled a series of holes in it
then used a old cut down broom handle and punched out the cat from the other side.
I then cleaned it up using a wood chisel to scrape off any missed bits, Top tip file off any Burrs before starting otherwise you will need one or two plasters


then put it back together and back to your friendly welder


lastly take it out to give it a good test, I took mine to Maroc and it was a awesome success, I have done about 6,500 miles and no issues