Road legal muffler?

**Amz** · 7th October 2010, 20:55

Hi guys, I just failed a warrant for my muffler on my 95 Honda XL250 Degree. It passed last time at the same place but they wouldn't this time. It's a homemade stainless job that is pretty much straight through but is perforated inside looking down it. Came on it when I got it but I also got the factory one. The factory one is really heavy and restrictive and makes the bike feel hesitant and sluggish. Maybe it has a catalytic converter in it, I don't know but it's heavy and feels really solid. What are my options other than refitting the factory one as is? What universal fit mufflers out there are road legal sounding yet good flowing performance? This XL is not your standard old XL. It uses the NX250/AX-1 DOHC motor so I doubt there are any direct replacements in NZ.

Cheers
Amber

**JATZ** · 7th October 2010, 20:59

Originally Posted by Amz

Hi guys, I just failed a warrant for my muffler on my 95 Honda XL250 Degree. It passed last time at the same place but they wouldn't this time. It's a homemade stainless job that is pretty much straight through but is perforated inside looking down it. Came on it when I got it but I also got the factory one. The factory one is really heavy and restrictive and makes the bike feel hesitant and sluggish. Maybe it has a catalytic converter in it, I don't know but it's heavy and feels really solid. What are my options other than refitting the factory one as is? What universal fit mufflers out there are road legal sounding yet good flowing performance? This XL is not your standard old XL. It uses the NX250/AX-1 DOHC motor so I doubt there are any direct replacements in NZ.

Cheers
Amber

Chuck your standard muffler on for the re-test, get a w.o.f. then come to Anatori this sunday.....

**scumdog** · 7th October 2010, 20:59

Fit some Pink Batts lining to it and try again?

**AllanB** · 7th October 2010, 21:05

Do a Google image search for 'DB killer'

Notice the insert is a small diameter pipe (25-30 mm) swelled or mated to a larger pipe that slips into and bolts to the outlet of your hell-raiser muffler.

Make one - it will shut it up heaps, and it is only a spanner away from removing it.......

**Amz** · 7th October 2010, 21:10

Chuck your standard muffler on for the re-test, get a w.o.f. then come to Anatori this sunday.....

Anatori ....yeah man I really want to but it also failed on the steering head bearings. I am gonna give them ago myself instead of taking it to a shop. Can't afford it. Can't be to hard. I have got it all apart to the preload nut. Do you just use a C spanner on them? Not sure if I have got one. I am expecting to see tapper roller bearings in there as opposed to loose balls but who knows. Hope I can get them of the shelf.

**YellowDog** · 7th October 2010, 21:10

I have a 40mm DB killer going spare if it will fit?

**Amz** · 7th October 2010, 21:49

Cheers for the offer of the DB killer. It unfortunately will be to big. I have just disassembled it. Turns out it has something similar to the DB killer in it but with no blank end on it. It is then inserted inside another gauze the length of the can. I only found a scruff of glass mat in there so the can is empty. Must have spat it out in it lifetime. Should I try packing it with pink batts. How long would that last. What material would be better long term. The measurements of the insert is 33mm, gauze 41mm, can end 75mm x 335mm.

**AllanB** · 7th October 2010, 22:02

Repack it and it will shut up a lot.

Don't use pink bats - they will just blow out the back in a pink haze.

You'll be able to buy a sheet of muffler specific packing from any decent bike shop - about $20 for a sheet and this will be enough. Wind it around the core as tight as you can - use stainless wire or masking tape to hold it in place and stuff the core back into the canister - it should be tight and you'll probably need to poke it in at the end.

**Taz** · 8th October 2010, 05:13

The stringy muffler packing is the best for four strokes. Pack it and it'll be all good again.

**AllanB** · 8th October 2010, 06:08

Originally Posted by Taz

The stringy muffler packing is the best for four strokes. Pack it and it'll be all good again.

Magoo mufflers have bags of that - again $20 ish.

**BuzzardNZ** · 8th October 2010, 07:12

insert a large banana in it, take it back and you'll get your WOF. Oh, wait, that only works on noisey diff's

**Amz** · 8th October 2010, 08:11

:-) I might try that.

**Taz** · 8th October 2010, 18:51

Good idea scooter boy

**Amz** · 8th October 2010, 18:56

Thanks for all your advice people. I repacked the muffler and eventually talked the wof guys into passing it. Sounds real nice now. I also replaced the top steering head bearing. Was easy. Hardest part was trying to source a replacement as you can't get them in NZ so went with a tapper bearing of same dimensions. Only thing I couldnt get was a new top seal.