540 muffler mod
if you pull the muffler you will see that the exhaust port discharges into a "cage" or insert inside the muffler. The bottom of this insert is pre-drilled with 3/16? holes and the top is solid. (This becomes the primary constriction in the system to the flow of hot gasses, and by restraining their expansion becomes a possible cause of heat buildup.) I grabbed a 1/8 drill and, working with the cage in the muffler, slant drilled the row of holes on each side until the inter-connecting steel broke. That left a small piece of steel at the front and back of the lower plate. I used an old wood chisel and hammer to slice thru the front piece, and a knife file to slice thru the rear piece (patiently). when free, the bottom piece drops down and can be pulled out. I left the top piece as is. Note that the two sides of the cage still interlock to form the structural "tubes" which hold the muffler bolts. This mod will pretty much put you at the limit of the Walbro WT carb. If you pull the whole cage, you'll need to cut some tubes to the same length to hold the muffler bolts, and you'll probably drop backpressure so much that you will need to add a larger carb or drill out the main jet, or bend the needle float upward. By that time, you'd want to get EH or Dan Henry or ? to play with one or both of the two transfer ports.
So now the exhaust gas can continue to expand straight out and downward into the fairly large main chamber in the bottom of the muffler. By that time the exhaust port is probably closed and the gasses would then equalize upward on the right side to the muffler port and out. I folded the cutout for the muffler port back out of the way. Using a bastard file, I filed down the removable cover for the muffler port, leaving a top length of about 1/4" That gives enough downward deflection the exhaust flow, to keep the cloud of gas away from my nose (to the extent possible)
If you get MX2T (colorless) and I use Amoco Supreme (also colorless, and it's supposed to be straight refined gas with no additives), you will notice you have almost no carbon exhaust munge buildup to foul up the screen (not true with Stihl, Husky etc 2-cycle oils - they will leave a trail of carbon grunge). and your plugs will be a nice warm brown.
the 540 seems to have the following timing, from TDC to BDC
intake port begins to close - 25.7 deg
intake port closes - 72.2 deg
exhaust port opens - 102.2 deg
transfer ports open - 121.3 deg
blowdown is only 19 deg, so there is potentially a lot of room here for some professional tuning. Also, the two transfer ports "aim" right at each other, so the two pulses of fresh gas would burst right "into each other faces" as it were, creating unnecessary turbulence. My suspicion is that the charge flow could be better organized as two complementary spirals, by angling the "roof" on one of the ports upward, leaving the other roof flat at its manufactured 90. the two pulses would now "wrap" around each other as they spiraled upward, one cw one ccw, upward from the back, pushing out the exhaust gas and reducing "mixing" by the wasteful mechanical turbulence caused by the current face-to-face construction. raising one of the transfer ports to angle its roof, would require raising the exhaust port, but it's probably already opening 12 degrees too late anyway.