It fell off!!!

[Spyke]

Hey Guys

I got a free kt250 not long ago and was as keen as to take it for a ride, I got the motor running did a bit of checking and took it to the local river.
I WAS HAVING A BLAST!!! until i heard the motor go alot louder and more poppy. I realised the muffler had fallen off and I couldn't find it so I'm making a new one.

The problem is should i make the inner muffer diameter smaller than the end of the inner exhaust diameter which is 26 mm. Or should I leave it at 26mm??? I don't want to have the bike with too much back pressure or too free flowing, it's hard to guess with my little knowledge.


all your help is much appreciated.

cheers :headbang: rock on fellow grease monkey's

[Motu]

An unmuffled KT is pretty damn loud! Best to go back and find it,they are a bit rare.

I made my own rear muffler for my KT250 before I located a genuine one.I made it from scrap stuff I had around at the time - a small car resonator,a rear baffle from some small Suzuki 2 stroke trail bike (the baffle you remove for cleaning).The inlet pipe has to do a tight turn around the rear shock,and is also a small dia - I used a front pipe from a Honda C50 scooter,being small dia with a tight bend.I brazed a washer over the end of the baffle to get the right restriction...and experimented with several sizes.Quite a bit of work,but not a problem if you enjoy doing that sort of stuff...and I do.

So the genuine article works much better and actually fits....I really think you should find your old one.

[Spyke]

cheers motu, I will try and find it, only problem in a public place and most likey someones seen it and threw it in the river for fun.

I've got the use of the school workshop, which is handy. I read theres a rule about the end diameter being a certain percent size of the header opening or something?

[Motu]

I've had a look in my junk,and it seems I no longer have the muffler,but still have the baffle.I'll take a photo tomorrow for you to look at....you'll see I've played around with it a lot to get it right.I also have a photo of the bike and OE muffler - I'm not sure what I did for the internal baffle....but for the end cap you can see I've just used a wheel bearing hub cap (off a trailer) and drilled a series of holes until I got it right.Near enough is good enough for me.

[Spyke]

cheers motu the photos are much apreciated.

[geoffm]

There are universal NZ made replacement mufflers from Musket
http://www.mlbnz.co.nz/mlbpdfsnew/MUSKET%202007%20CATALOGUE.pdf
Geoff

[Spyke]

Hey guys, I emailed this guy called Fred that I've heard about as he makes kt250 parts and he has been more than helpful. Hes going to email me the inner dimensions, so when I've made it I'll post a pic of the final results.

cheers.

[cs363]

You could give Egmont Village Bike Parts a call - they were wrecking a KT250
Contact Bill, Free Phone 0800-142-453, phone & Fax 06-752-2862, Email: evbp@paradise.net.nz

[Spyke]

Thanks cs363

I'm trying to make a muffler at the moment but if I fail I'll diffeinately give that a shot.

Does anyone know where to get old baffling???

[Spyke]

Hey guys I've made it. It isn't pretty :whistle: and it hasn't been panted but its been tested successfully at the river.

basically a strait through pipe with a little blocker to make the air go out around through the baffling. brings the exhaust noise level down heaps, now only a way to shut the engine noise up! man the motors loud.

cheers:rockon: