98 450ES muffler needing help - Honda ATV Forum
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post #1 of 12 (permalink) Old 04-16-2019, 11:16 AM Thread Starter
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98 450ES muffler needing help

My 98 450ES muffler has had the main baffle loose and sticking out of the back. It is noisy and rattles when running. I was gonna use JB Weld high temp and try to attach it for a cheap fix, but went to our local welding shop and said better to TIG weld it. He said he has to have it removed to fix as his welder is towards the back of the shop and no way could the Honda be pushed back there. I went out this morning and decided to see if I could remove, the 2 bolts that hold the muffler to the frame came out easily. Looked at the 2 bolts holding the pipe to the exhaust pipe and not so pretty! Sprayed some penetrating fluid on them and let sit for awhile, came back and they squeaked some but eventually backed out. After some twisting and turning I finally got it loose. I looked up the muffler at Partzilla and almost fell over, lists for $897, they sell for $621!! Oh good grief this old part is gonna get fixed, he said $25. I know OEM parts can be overpriced but this is crazy...

1998 Honda Foreman 450ES
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post #2 of 12 (permalink) Old 04-16-2019, 11:45 AM
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Ya crazy. Honda don't want to sell mufflers for any ATV apparently, they're all blue-sky priced like that. The repairman might have to cut the end cap off of your muffler to fix the rattle, cause there is a baffle inside that usually rusts loose and rattles like crazy until you remove it. So pass on that tip in case he don't know about that baffle already.


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post #3 of 12 (permalink) Old 04-16-2019, 01:33 PM Thread Starter
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It does rattle inside besides the baffle that is loose and sticking out the back. Guess I should go see him and see what he thinks...

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post #4 of 12 (permalink) Old 04-16-2019, 04:56 PM
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mail It to me, i'll fix it..lol.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #5 of 12 (permalink) Old 04-16-2019, 06:13 PM Thread Starter
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hahahaha had I known before if I had brought my engine down to you I could have thrown the muffler in there....but then I had to go and fix my engine myself.....

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post #6 of 12 (permalink) Old 04-17-2019, 05:22 AM
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hahahaha had I known before if I had brought my engine down to you I could have thrown the muffler in there....but then I had to go and fix my engine myself.....
lol. well, I have cut the very ends off some mufflers, and gutted the bad pieces in them, and welded the end back on, i've got a few pics in some build threads from me showing how I did this. all you need is a wire welder, a angle grinder or a Dremel with a lot of cut-off wheels, cut the weld all the way around the very end of the muffler, yank that crap out, weld the end back on. it made no difference on how the engine ran after I welded the end back on !.
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post #7 of 12 (permalink) Old 04-17-2019, 10:26 AM
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My 98 450ES muffler has had the main baffle loose and sticking out of the back. It is noisy and rattles when running . . . went to our local welding shop and said better to TIG weld it. . . .
I looked up the muffler at Partzilla and almost fell over, lists for $897.- they sell for $621.- Oh good grief this old part is gonna get fixed, he said $25. I know OEM parts can be overpriced but this is crazy...
Would you take some pics of the fix if possible.
I have two of the OEM's . . . both need welding.
Was going to cut the side off that's hidden by the heat shield, just haven't done it yet.
Did get a Kimpex replacement muffler for 1/3 the price of Partzilla's OEM.
They are a perfect fit . . . just like an OEM would fit. Made of heavier gauge steel also.
Living in Canada, and Kimpex is Canadian, it saves quite a bit in the $$ exchange and import, etc.
Good luck, and pic's ?

'99 Honda Foreman 450ES
'99 Honda Foreman 450S ....
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post #8 of 12 (permalink) Old 04-17-2019, 05:39 PM Thread Starter
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Here's a pic of the fix, maybe not pretty but it's not coming back out...
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post #9 of 12 (permalink) Old 04-18-2019, 07:15 AM
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Here's a pic of the fix, maybe not pretty but it's not coming back out...
looks good too me !.

'89 trx350D foreman 4x4...'85 vf700c magna, '03 trx450fm foreman 4x4 , 2015 Yamaha waverunner fx cruiser ho, '08 vt750c2 shadow spirit
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post #10 of 12 (permalink) Old 04-18-2019, 08:51 AM Thread Starter
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Here's a pic of the fix, maybe not pretty but it's not coming back out...
looks good too me !.
He said the muffler and baffle were different metals so a little more of a challenge....much easier to weld like metals..

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