I recently purchased a used TRX250X, and noticed a significant air leak in the exhaust where the exhaust muffler joins to the main exhaust pipe.
(Side note - I just rebuilt the carb and was making sure it ran properly when I found the exhaust problem)
This parts diagram shows the area I am referring to, and I'll just use the #'s of the parts for clarity.
https://www.bikebandit.com/oem-part...250-trx250x-exhaust-muffler/o/m151653sch93278
The exhaust muffler pipe (#3) , goes over the main exhaust pipe (#5) that leads to the engine. It has a band/clamp (#8) that sits around the exhaust muffler side of the pipe and where the two connect, you tighten it to hold them together.
Based on this diagram and the service manual, it would appear that there's another part (#10 - the muffler gasket) that is missing that is supposed to go in there. Instead, the previous owner had put a silver/reflective looking tape (I think it might be this stuff? https://www.motosport.com/dei-cooltape ) around the two pipes #3/#5, and then put the band/clamp #8 over the tape/pipes.
So, What I did was buy a replacement for the missing piece.
https://www.ebay.com/itm/HYspeed-Ex...e=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649
I thought this was the right piece, and i installed it over the end of the exhaust pipe (#5), which went into to the exhaust muffler (#3),
I then wrapped it with https://smile.amazon.com/gp/product/B000E283S0/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1 to make sure it was sealed tight, then tightened the clamp (#8) over the tape where both ends are connected.
I started it up and let it idle for 4-5 minutes and was adjusting the idle and revving a bit, when i noticed smoke coming out of the middle of the exhaust. The spot where the muffler gasket was installed, looks like it was melting and bubbling up through the tape. I turned the motor off and am letting it cool down, and figured I'd ask here before I started doing more stupid stuff.
Did I get the wrong part? Install it wrong?
(Side note - I just rebuilt the carb and was making sure it ran properly when I found the exhaust problem)
This parts diagram shows the area I am referring to, and I'll just use the #'s of the parts for clarity.
https://www.bikebandit.com/oem-part...250-trx250x-exhaust-muffler/o/m151653sch93278
The exhaust muffler pipe (#3) , goes over the main exhaust pipe (#5) that leads to the engine. It has a band/clamp (#8) that sits around the exhaust muffler side of the pipe and where the two connect, you tighten it to hold them together.
Based on this diagram and the service manual, it would appear that there's another part (#10 - the muffler gasket) that is missing that is supposed to go in there. Instead, the previous owner had put a silver/reflective looking tape (I think it might be this stuff? https://www.motosport.com/dei-cooltape ) around the two pipes #3/#5, and then put the band/clamp #8 over the tape/pipes.
So, What I did was buy a replacement for the missing piece.
https://www.ebay.com/itm/HYspeed-Ex...e=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649
I thought this was the right piece, and i installed it over the end of the exhaust pipe (#5), which went into to the exhaust muffler (#3),
I then wrapped it with https://smile.amazon.com/gp/product/B000E283S0/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1 to make sure it was sealed tight, then tightened the clamp (#8) over the tape where both ends are connected.
I started it up and let it idle for 4-5 minutes and was adjusting the idle and revving a bit, when i noticed smoke coming out of the middle of the exhaust. The spot where the muffler gasket was installed, looks like it was melting and bubbling up through the tape. I turned the motor off and am letting it cool down, and figured I'd ask here before I started doing more stupid stuff.
Did I get the wrong part? Install it wrong?
