[Stephan28]

I’m curious what options are available to replace the stock muffler? Any aftermarket bolt on units that are truly bolt on and don’t require jetting to make work?

I’m pretty sure mine is going to need to be replaced in the not so distant future. The cleanout plate for the flame arrestor is missing because the internal nuts broke outside the plate is MIA.

 

[TBRider]

Your best bet is to look for a decent used stock exhaust, it's not a race bike...

 

[Stephan28]

Your best bet is to look for a decent used stock exhaust, it's not a race bike...

I’m not looking for a race muffler at all. I’m looking for a bolt on replacement like stock. Obviously the originals aren’t available new anymore and used OEM ones are upwards of $200 on fleabay. Who knows how long they are going to last. Some of them already are burned/rusted through. I saw a couple of aftermarket types there that appear to be somewhat like a stock muffler.

I was just wondering if anyone here has a recommendation or has used something other than an old stock muffler with good results? Maybe someone knows a place that rebuilds them?

Here is one I found but I have no idea how good or bad it might be.

https://m.ebay.com/itm/KImpex-Muffl...-651-Honda-TRX-350-1986-to-1989-/202249788770

 

[alloutdoors]

I’m curious what options are available to replace the stock muffler? Any aftermarket bolt on units that are truly bolt on and don’t require jetting to make work? I’m pretty sure mine is going to need to be replaced in the not so distant future. The cleanout plate for the flame arrestor is missing because the internal nuts broke outside the plate is MIA.

I think OEM/stock would be a great option, but do know my local muffler shop will take on such a task, so you might consider visiting a few "muffler" shops locally and see if anyone is willing to take on such a task, because they could cut/modify components off the original one.

 

[Stephan28]

I’m curious what options are available to replace the stock muffler? Any aftermarket bolt on units that are truly bolt on and don’t require jetting to make work? I’m pretty sure mine is going to need to be replaced in the not so distant future. The cleanout plate for the flame arrestor is missing because the internal nuts broke outside the plate is MIA.

I think OEM/stock would be a great option, but do know my local muffler shop will take on such a task, so you might consider visiting a few "muffler" shops locally and see if anyone is willing to take on such a task, because they could cut/modify components off the original one.

Hey, that’s a pretty good idea. I’ll definitely add that to the list of possibilities! Only problem is that I’ll have to find a shop that is not only willing to take it on but is capable of doing so with decent results.

 

[Duck0fDeath]

The two bikes of mine that had a muffler are both missing that cover. Should be easy to make something that will work fine. It's just a small rectangular piece of metal with two screw holes. I also patched a 7" gash in one using JB weld, then painted with high temp paint.

 

[Stephan28]

The two bikes of mine that had a muffler are both missing that cover. Should be easy to make something that will work fine. It's just a small rectangular piece of metal with two screw holes. I also patched a 7" gash in one using JB weld, then painted with high temp paint.

Just regular 2 part JB Weld? Extreme Heat Paste? High Heat Putty? There are like 15 varieties nowadays.

 

[Goober]

One of mine broke too. You need that cover to be removable for the carbon blowout hole—spark arrestor is needed for trail riding forest or grasslands but how many of them work lols. Drill and tap I think it’s 6mm and get replacement Honda flange bolts and try to score another plate. That’s the OEM way.

You can also make the plate from thin steel plate and buy flange bolts. They won’t look the same as Honda bolts but it will be a clean and useable fix

 

[SamUK]

There’s a good used OEM muffler on ebayUK at the moment £45 I think it was. Might be worthy of a look see if it’s of any use to you. Same guy had the heat shield too.

 

[Duck0fDeath]

I think I used the standard formula JB weld. Same stuff I used on a gas tank repair. I haven't tested the repair yet on the muffler but I'm putting the motor in today. I'll let you know. The stock muffler uses fairly thick gauged metal. I was surprised to find how stout it was. They clean up nice and shiny with a wire wheel too.

 

[Stephan28]

I think I used the standard formula JB weld. Same stuff I used on a gas tank repair. I haven't tested the repair yet on the muffler but I'm putting the motor in today. I'll let you know. The stock muffler uses fairly thick gauged metal. I was surprised to find how stout it was. They clean up nice and shiny with a wire wheel too.

Keep me posted! Thanks!

 

[Stephan28]

One of mine broke too. You need that cover to be removable for the carbon blowout hole—spark arrestor is needed for trail riding forest or grasslands but how many of them work lols. Drill and tap I think it’s 6mm and get replacement Honda flange bolts and try to score another plate. That’s the OEM way.

You can also make the plate from thin steel plate and buy flange bolts. They won’t look the same as Honda bolts but it will be a clean and useable fix

I was able to find and order the gasket, plate and hardware online. However, I’m afraid there is at least one broken bolt shank inside the muffler that I’ll have to try and drill out someday. That should be a fun exercise.

 

[retro]

I have an old aftermarket Cobra muffler on my 87 that is a bolt-on. Sometimes you can find them cheap on fLeebay. I had to make my own muffler-to-header pipe gasket though... as I didn't want to waste time and money on a china gasket. no rejetting required and the spark arrestor is removable for cleaning.

 

[Duck0fDeath]

I've gone through about 2 dozen drill bits on these two project bikes so far by drilling out various seized and broken hardware. Good times.

 

[alloutdoors]

that’s a pretty good idea. I’ll definitely add that to the list of possibilities! Only problem is that I’ll have to find a shop that is not only willing to take it on but is capable of doing so with decent results.

You may find some bright spots out there when you start looking around within the community....

 

[Mossyman]

From what I was told mine came off an old Volkswagen...works really well though :grin

 

[Stephan28]

I have an old aftermarket Cobra muffler on my 87 that is a bolt-on. Sometimes you can find them cheap on fLeebay. I had to make my own muffler-to-header pipe gasket though... as I didn't want to waste time and money on a china gasket. no rejetting required and the spark arrestor is removable for cleaning.

Would you happen to have a link to that muffler per chance?

 

[Stephan28]

Adding a photo:

The bolts appear to be broken off inside and there is quite a bit of rot out in the same area.

 

[retro]

Would you happen to have a link to that muffler per chance?

They aren't made anymore as far as I know..? Mine was on the bike when I got it. Here is a before pic (before a long vinegar bath) of my rusty Cobra muffler:

http://www.hondaatvforums.net/forum...rap-heap-rescue-restoration-3.html#post911562

and here it is again after derusting and refinishing with the spark arrester apart and lying next to it:

http://www.hondaatvforums.net/forum...rap-heap-rescue-restoration-3.html#post915273

and again after being mounted on the bike:

http://www.hondaatvforums.net/forum...rap-heap-rescue-restoration-3.html#post919058

A stock muffler might be a quieter muffler if you can find one in good condition, but this is one more option to consider if you can't find a decent one.

How is your gas tank looking inside? Those are found rusting out too, on many old bikes.

 

[Stephan28]

There?s a good used OEM muffler on ebayUK at the moment £45 I think it was. Might be worthy of a look see if it?s of any use to you. Same guy had the heat shield too.

I looked and could not locate it. Probably sold already for that price.