I just got a 2002 model last week.Looking at the pics of new bikes I see the end cap of the muffler has the small pipe
sticking out.On mine the end cap has a recess of about 3 inches to the small pipe.End cap looks normal not butchered,
but then I haven't seen any other 500 mufflers.The stampings are model 1 B 1 and kaw1620500 on both sides.Any ideas?

 

Perhaps someone did a little cutting?
The EX500/Ninja 500R has had zero changes (aside from color and nomenclature) since 1994.
All of the mufflers look like this, unless they've been modified or replaced (uncrushed of course):

 

http://wm14.inbox.com/thumbs/33_3c43...b_tn.jpg.thumb

Looks too good for a cut job.I'll get a pic and post.

 

ahorizontal bandsaw will make a perfect cut..

skilled ppl woth any saw or cutoff wheel can make perfect slices.. probably a modded stock can..


btw..
welcome to KF!!