Ok- been studying posts and seems if I make clean, proper size hole and get in deep enough-the straw/tip will be able to come right out (old David R post) but I also, at that point have killed the spark arrester.

Is this true???????

 

Holesaw will have to cut through two layers of steel. The inner layer is way in there,so you need to cut the straw as short as possible to get the saw in deep enough. Holesaw will not disable spark arrestor, 1/2" drill will disable spark arrestor.
marc

 

When i did my KLR once i got the hole saw all the way through there were a few spot welds on the other end of the center pipe, a little working back and fourth broke them free.

 

Thats how i did my klx as well except with a torch on the end cap.