Ducati Monster Forum

Have cored my cans just recently, will post some pics and more tips shortly.

first remove cans from bike, wrap them in something to protect the outside.

1: look in to end of can, you will see 2 little welds.
2: with your dremel cut them through.
3: remove the inner end piece,
4: you will see two more brackets holding the end cap on, cut these.
5: with a little effort pull off the end cap.
6: slide the inner stainless can out of the aluminium surround.
7: cut off end of can with drop saw.
8. cut off as much as you can of the longest tube you see.
9: slide it all back together.
10: high temp silicon and some rivets to hold the stainless end to the can,
11: reassemble
12: go wake the neighbours.

Tips:
Careful with overtightening the exhaust clamps, put a bit of never seize on the bolts.
Before putting in those rivets have a look first to see that they will be hidden after reassembly.
If the inner end piece is still in good condition you can use it to quieten things down a bit by sticking it back in place
with a small rivet.

(http://i298.photobucket.com/albums/mm259/andrewb172/mods/th_6.jpg) (http://i298.photobucket.com/albums/mm259/andrewb172/mods/6.jpg)
(http://i298.photobucket.com/albums/mm259/andrewb172/mods/th_81.jpg) (http://i298.photobucket.com/albums/mm259/andrewb172/mods/81.jpg)

Some photos from "that other website" thanks to the nice person who posted them. They were a great help in visualising
what was inside.

That was me that posted that originally,if the mods on this board want all that info again just let me know and I'll send it over.

http://www.ducati-upnorth.com/tech/coringsr.php

Its also posted here.

Taking an opportunity to thank you in person, thanks Monstyr  wt:

Hello Lads (and ladies)...want to core out my cans on my stock 2004 s4r and have went through the previous posted instructions and photos, a huge help so far; however, I'm not very sharp and have a question regarding one of the last steps in the process. Can someone explain exactly what to do with the baffles? Am I yanking them right out and then running a new pipe all the way through, or am I just cutting the longest pipe back as far as it can go. The pic's don't show that far into the cans. Any help would be great. Tks Ebs

depeends on what you want to do. If you want it to be louder, you dont need to cut it all the way back, simply cutting that connection to remove the end cap will result in a louder bike. if you want to repack it then you need to cut as much stuff out as you can so you can insert a new perf tube.

I found out the hard way that 2007 S4rs cans won't fit a 06 S2r100. I picked up a set on Ebay and found the pipe going in is much larger. All the posts I saw while researching this said they were the same. I am coring them anyway to understand the process, but will be selling them after I'm completed if anyone is interested. Contact me at
caryd@cox.net.

My favorite way is once you have the can apart and on step #8 cut off as much as you can of the longest tube you see. Don't do it. 

Instead take a cut off wheel on a grinder and cut out the entire insides of the inner sleeve with the baffles so all you have left is the end cap with a finger of metal that contains the mounting points for the can and heat shield.

Then slide the endcap (with fingers of metal) into the Aluminum shell of the can, The can's installation bolts will hold the front end caps on.

Order some 2" perforated tubing from a Harley shop, cut to length and install this connecting the two end caps.  Get some FMF four stroke exhaust packing and pack the can or wrap the perforated tubing to get a deeper sound

Now resume with step 9.

You will knock 10 lbs off the back of the bike, get some good tone and have some factory cans that rival anything you can buy. 

The last bit where the can is rebuilt is here, I didn't photograph it but the diagram should explain things.
http://www.ducati-upnorth.com/forum/showthread.php?t=7504 (http://www.ducati-upnorth.com/forum/showthread.php?t=7504)

Thank you for posting.  That last image with the diagram was very helpful.

Brimo's is only a partial core - if you want to do a full core job, use his instructions combined with mine posted here: http://www.ducatimonsterforum.org/index.php?topic=56506.0 (http://www.ducatimonsterforum.org/index.php?topic=56506.0)