Hi all,
I agree with Dave lets just get on with it,
firstly even if your muffler is brand new pull it apart see how it is packed in my experiance mufflers staight from the factory are packet badly usely way too tight,I had bad noise problems with brand new pro circuit mufflers which went 106db on a modern KX85 the owner was going to send it back as the pipe and muffler cost $1200.00 each he had two bukes,but on closer examinatin we pulled it apart and it might not have been packed as the packing had been jambed in way too tight, we repacked it with some wool packing, not too tight or all the noise goes straight out the back not through the packing ,result 97.9 db which is a pass.
Second check your perfeated tube and drill out your holes as big as possible, uselly when they are new they are about one eighth, drill them out to about a quarter as big as you can do every hole repack again and you will notice the difference even on an old muffler.
If you are making a new muffler make it as big as you can, uselly two stroke mufflers are two short, most of the muffler is in behind the side panel and you dont even see it anyway The longer you make it the quieter it will be if you follow steps one and two as well.
four stroke bikes are the same except you can gain even more as much as 5 db by rapping the outside of the pipe with a suitable thermal rap,this is the cheapest and easiest way of making a four stroke queit.
I got my old XL350 from 114db down to 98.9 by doing every thing I listed above drill tube,repacking and rapping the pipe. Cost $80.00 and a bit of time it is really that easy.
Cheers
Fatboy