**First let me say, some of the pictures are courtesy of cafercr35 from sportbikes.net.**
1) First things first.
You need a muffler from a 06 and up R6r
2) Prepping the new muffler
You need to cut 2 and 7/8 inches off. The part with the exup/butterfly flap is what needs to come off. Start measuring from the lip.
Dispose of the exup/butterfly flap piece.
Next I cut off the hanger on the muffler as well. To me it wasn't a huge problem with it not being the cleanest cut, because it is hidden, and the cut will not be visible.
3) Prepping the bike
Now is, what I thought to be, the hardest part. You need unbolt the support for the exhaust pipe. (blue circle on the right)
Next you need to literally pry down the pipe that is on the bike down from its original position about an inch or so. The goal here is to set the hanger that is on the manifold on the bottom of the hanger that is on the bike; wedging it if you will....
Now there's a few ways of performing the next task...
***It's important to understand that the whole manifold is still very secure even with the removal of this hanger***
You can fabricate something to secure the pipe from moving back to its original position, like this. This is really the better thing to do.
Or what I did is I used the original bolt I took off that supported the pipe and put a huge washer on it and fastened the bolt right back on, with the pipe under it. The purpose being that it will not bump over and slide into the original position (if it did slip over, it would cause the new pipe to hit the swing arm). This worked just fine for me!
4) Fitting the new, prepped, muffler on the bike
The outer diameter of the muffler is 2 inches. The inner diameter of the stock exhaust is 2. It does fit. What some people will do is apply a relief cut at the end of the pipe (the pipe that is on the bike itself) for extra clamping power. However, the clamp I used (pictured below) allows for more than enough clamping power.
Now bolt everything back up!
Q- Is there a lack of support for the mufflers weight? (If you went the washer route)
A- No, it would probably take at least 50 pounds to move the thing.
Q- Does it rub on the swing arm?
A- I had about a half inch clearance, with full travel of swing arm.
Q- Does your foot hit the can?
A- I wear size 11, and the back of my shoe made contact maybe twice while the time I owned the bike.
Q- Will the heat from the new muffler damage my plastic (because it is closer)?
A- No. There is a black metal shield at the base of the new muffler. This piece will be the only part that will make contact with your plastic. It acts like a heat shield, it will not get hot enough to cause damage.
A better sound clip courtesy of endosj3