Your right, sometimes I am a little thick, so now its just the muffler hole size..... these are the 1600 and 1700 mufflers rphazen had posted on his site. they appear different diameter.(ignore the stage 1 holes) or is it the pic?




https://pbs.twimg.com/media/DE8qGqMUAAAnI6n.jpg

here is a pic of 1600 and 1700 mufflers,I measured a 1700 as I have one it is 34mm at the opening, anyone got a 1600 they could measure?

I just pulled out the 1600 mufflers from my '02 R*. Outlet end (noisy end) is resessed so my measurement may be off some but is way smaller than 34mm. Best estimate/measurement is 20mm (3/4" diameter. Hope this helps.

I have a complete 1600 stock system I can measure the headpipes on after work.
I'm positive they're all the same size but I'll measure them to verify that.

OK, got home last night later than planned & didn't feel like climbing through the barn in the dark.
So at work today I just looked up something that would determine the pipe diameter difference, or lack of it.

Exhaust gaskets.
If they aren't the right size they won't fit & won't seal.

Same part # 3EG-14613-00-00 that fits a 2014 Roadstar 1700 also fits a 1999 Roadstar 1600 as well as the Roadstar Warrior.

The same exhaust gasket also fits all years of Raider, Raptor 700, Grizzly & Kodiak 700, Virago 700/750/920/1000/1100, all years of the Bolt 950, all years of Roadliners & Stratoliners, all Stryker, V-Star 950/1100/1300, as well as all the Viking & Wolverine Side X Sides.

The gasket between the headpipe & muffler list is a bit shorter but still shared by all V-Star 1100 & all Roadstars 1600/1700 except Roadstar Warrior.
That part is # 5KS-14755-00-00 if you're curious.