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Discussion Starter #1
Bit of a strange question, I know, but is there any way of making the standard exhaust any quieter? I’ve removed / checked over, the end can, and as is obvious, it’s a welded fabrication, no baffle to wrap. I love the bike, but on a touring run, I get a bad headache. I’ve resorted to custom earplugs, balaclava, and a ‘helmet pelmet’, which has reduced the problem. If no way, I guess it’s the alternative aftermarket end can.
Thx
 

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Stock exhaust is pretty quiet, you're more than likely hearing more intake noise than exhaust. Wind noise is likely your biggest impact. A better helmet perhaps.
 

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I'll echo Bearded above, the stock exhaust is quiet and it may be the whine of the intake or other sources of noise. I'm not sure you'd find an aftermarket exhaust that is more quiet, but you'd find one that changes the tone of the exhaust note. Maybe you're sensitive to certain frequencies and changing the note would help. But it's an expensive gamble.

If you have the wrong helmet (shape, size, etc.) you can experience lots of wind noise inside the helmet. For example, my race helmet, which is designed for a tuck position, is very loud in an upright position. I had to buy a new helmet, one designed for a more upright riding position, when I bought my GSXS.

Generic ear plugs cut certain frequencies and allow others. Again, you could be sensitive to frequencies that ear plugs are bad at eliminating.

In any case, if you think it's sound that's causing the headaches, you should consult a specialist and get it sorted out.

But what if it's not sound that's causing the headache? What if it's something else and, then, after the onset of a headache you are becoming sensitive to sound? What if your helmet doesn't fit correctly and it's putting pressure somewhere? What if you're riding "stiff" and don't realize it? Clench your jaw while riding? If you wear glasses or contacts, is your prescription up-to-date? Are you sensitive to the sun (or UVA/B rays)? Does your visor filter the sun? Perhaps it's the vibration at the handlebar or footpegs.

I get congested when I ride in temperatures below 80F degrees so I have to take a decongestant or close the chin vent on my helmet. If I don't, that stuffy nose leads to a headache.

Hope this helps, and good luck sorting this out.
 

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If you're considering aftermarket cans, I have a full M4 exhaust. Combining with a stage 2 baffle, the wind noise is actually louder than the exhaust at freeway speeds, a far cry from the obnoxiousness of the stage 1 or no baffle. YMMV given different helmets though.

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Lost makes some good points here. I use a balaclava in the cold weather and that extra bit of thickness comes close to making my helmet too tight. One time when I had the hem of the balaclava face opening a bit too high it gave me terrible headaches (right on the forehead).
 

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The headache Might be coming from your neck muscles?
Also I’m running the stock exhaust and I wouldn’t want it any quieter.
 

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suzuki sell a tall screen, might help with lessening the amount your neck muscles strain to hold your helmeted head against the wind, as to quietning the stock muffler, its possible, a tubed insert that reduces outlet flow by approx 1/4 will help reduce noise, but it could also affect the fueling
 

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I, for one, think the stock exhaust on the GSX-S is plenty 'loud' for a factory pipe. It truly surprises me at times. It's not obnoxious or anything, but it is the loudest stock pipe I've ridden, especially when there is something to reflect the sound back to me, like a canyon wall or tunnel. I can understand the OPs desire to be quieter. I think @lost was onto the right solution - an after market pipe producing a different "tone" could help and @gsxsdave pointed out that the M4 pipe with the stage 2 baffle would be quieter than stock. Seems weird replacing the stock pipe with an aftermarket one to get QUIETER, but in this case, that might be the fix that's needed.


The aftermarket pipe inserts (baffles) usually have a screw that holds them in. I wonder if the OP could just drill a hole and buy an insert to fit into his stock exhaust pipe to get the quiet he wants? Something like this:
https://www.revzilla.com/motorcycle/vance-hines-quiet-baffle-for-competition-series
Finding something that will fit into the stock exhaust 'hole' and then affixing it in place would be the trick. I can't really help there. Just tossing out an idea to consider.
 

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You could always buy an aftermarket tailpipe with removable baffle and wrap the baffle in the sound deadening wadding.
 

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….what ever you do, keep wearing the ear plugs regardless,....is not the engine, nor the exhaust the killer...….it is the wind noise... The human head was not designed to cut through the air at this speed. When you get older, you might be able to hear if you do.
 
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