[bcsman]

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...

 

[retro]

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.

 

[bcsman]

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...

 

[shadetree]

mail It to me, i'll fix it..lol.

 

[bcsman]

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.....:wink

 

[shadetree]

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.....:wink

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 !.

 

[Macarena Man]

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 ?

 

[bcsman]

Here's a pic of the fix, maybe not pretty but it's not coming back out...

 

[shadetree]

Here's a pic of the fix, maybe not pretty but it's not coming back out...

looks good too me !.

 

[bcsman]

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..

 

[Macarena Man]

Both of mine have stuff broken off inside. They look good from the outside. I'll cut one open soon . . . will post pics.

 

[bcsman]

Yeah I didn't catch my guy before he had welded the baffle to see if he could cut it open. So I still have rattles so will be interested to see what yours looks opened up.....