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I have an 02 1150R with a Laser Duo Tech exhaust. When I leave the insert in, it seems to have a lot of sooty carbon collecting on it, but when I take it out, it is just a bit too loud on the highway for long periods of time. I wondered if drilling holes in the insert would be a happy medium for me or is there some other adjustment that should be made?
If drilling out the insert is a good answer, how many holes and about what size?

Which of the two inserts are you referring to? Do you have both inserts?

The only insert that I have is the one with about a 45 degree bend, I think there may also be a straight insert available, but thought drilling holes in the one I have might be something to try.
I haven't checked too close, but the bend in the insert may only be because of the angle of the outlet on the muffler.

The bent insert is the Street insert, the straight one is the Race insert. The bent "Street" insert just keeps the sound level lower because its not a straight shot through the exhaust. I'm not sure what drilling holes in your Street insert would do, but it may make it louder as you suspect.

http://www.laser-exhausts.com/wp-conten ... ochure.pdf

Baffle out + earplugs would be my solution. Mind you, I run the same Laser slip-on and have the street-legal baffle in....