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Old November 6th, 2018, 04:28 PM   #1
Fifthwheelman
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Winter rebuild time. With questions and updates.

Ok so I am finally ready to admit my personal riding season has ended...but on the plus side itís rebuild/maintenance time.

Iíll post the full to do list as well as progress as it happens but I need info to start one major part.

I hate the way my exhaust sounds (wait donít click away!) itís too -redacted- loud way way too loud. Iím struggling to find an exhaust rebuild thread that is aimed at making quiet all I can seem to find is aimed to make loud. Should I just pull the mufflers and repack them? Potentially have things welded? Iím useless at exhaust.
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Old November 6th, 2018, 04:32 PM   #2
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Stock pregen mufflers are not loud. Has someone modified it, for example by drilling out the four rivets on each muffler? Or maybe even something worse.
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Old November 6th, 2018, 04:36 PM   #3
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These holes?
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Old November 6th, 2018, 06:18 PM   #4
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Endcap is missing
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Old November 6th, 2018, 06:58 PM   #5
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more missing than just endcaps, that thing is gutted.
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Old November 6th, 2018, 07:54 PM   #6
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You need cap and small tube to connect to inner tube shown.
Surely someone has set in box somewhere they're not using?
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Old November 6th, 2018, 09:11 PM   #7
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Is there a diagram of the complete muffler assembly? Preferable blown apart to show all the pieces?
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Old November 7th, 2018, 06:07 AM   #8
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I've never seen a diagram, as they are a one piece welded unit from the factory, I doubt one exists. Your best bet is to locate a pair of used mufflers.


Here's a few pics I took of one I opened up on the inlet side

https://www.ninjette.org/forums/showthread.php?t=322941
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Old November 7th, 2018, 06:20 AM   #9
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Pretty sure I can cut mine open have the center perfed pipe welded in place and then weld em back together for close to $50 should I add some muffler pack material around the center?
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Old November 7th, 2018, 06:41 AM   #10
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Do what you want, but I've seen people giving pregen systems away for free.
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Old November 7th, 2018, 07:00 AM   #11
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I'm looking at set of EX500 mufflers. They appear to be similar and might fit. I'll try to swap them in over weekend. If they do fit, they're yours for cost of shipping.

Interesting that new-gen with single muffler is actually quieter than pre-gen with two... hmmm...
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Old November 7th, 2018, 07:06 AM   #12
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I have no effective words for that offer...thank you @DannoXYZ
@Z1R rider where? Just asking because finding deals is a weak point in my skill set.
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Old November 7th, 2018, 07:32 AM   #13
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Quote:
Originally Posted by Fifthwheelman View Post
@Z1R rider where? Just asking because finding deals is a weak point in my skill set.

On this site sometimes, they're a helpful bunch! My son picked up a set from one of the members on here, for free as they were cleaning the garage. I've seen them on ebay for next to nothing at times, shipping may be prohibitive, I've never looked into it. You could post up in the "Items Wanted" section here and see what shakes out. Also keep an eye on the "Free Stuff" section.
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Old November 7th, 2018, 09:11 AM   #14
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Found a full set on eBay for around $45 didnít ask shipping have to wait and see wether my attempted home brew muffler repair works.
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Old November 8th, 2018, 08:14 AM   #15
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To do list: strip all plastic off (done)
Remove carb (done)
Send carb off for fixen
Re align tire and make direction correct.
Remove and clean air box
Replace fluids and filters.
Repair cracked plastics
Re lube things.
Loctite things.
Rebuild/replace mufflers
Remove mufflers (done)
Gaze wistfully at the most-of-a-cycle and dream of riding season (current)
Put back together
Adjust valves (thanks for the reminder jkv45)
RIDE!
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Old November 8th, 2018, 08:18 AM   #16
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I'd also check the valve clearances while you have everything apart.

https://faq.ninja250.org/wiki/Hints_...lve_Adjustment

https://faq.ninja250.org/wiki/J_Valve_adjustment
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Old November 8th, 2018, 08:21 AM   #17
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Pic 1 Getting naked.

Pic 2 and 3 heat damage?

Pic 4 crack needing fixed. Abs correct?
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Old November 8th, 2018, 08:23 AM   #18
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Re align? Iím not seeing any frame twisting or bends
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Old November 8th, 2018, 08:24 AM   #19
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Ewww gross need to pull and clean airbox...speaking of who decided to put it there!? So much trouble to pull carb
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Old November 8th, 2018, 08:26 AM   #20
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The potential source of my woes lookit the disintegrating foam in the tiny holes
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Old November 8th, 2018, 08:29 AM   #21
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Little tube inside the muffler appears perforated which side (back or front) of the muffler does it attach to normally? Thinking of cutting at the weld my finger is on to have it re welded in place and then the cut weld re welded. Just a thought.
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File Type: jpg 1F099F9F-5046-4156-A209-3E81D4616F7E.jpg (64.6 KB, 2 views)
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Old November 8th, 2018, 12:25 PM   #22
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The pics in the link (#8 above) are what I found cutting the front weld, I never did cut the rear one. The way it looked to me is the tubes and baffles in the muffler are all spot welded in place and would be pretty hard to take out without destroying the muffler. Of course the ones you have look to be gutted, with all the baffling and routing tubes removed by whatever means. It is tough to beat the performance of the factory engineered stock mufflers.
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Old November 8th, 2018, 02:51 PM   #23
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Quote:
Originally Posted by Fifthwheelman View Post
Little tube inside the muffler appears perforated which side (back or front) of the muffler does it attach to normally? Thinking of cutting at the weld my finger is on to have it re welded in place and then the cut weld re welded. Just a thought.
I don't think you have to cut front weld. Perhaps cut rear-weld to get centre tube down to meet original and to install cap.

But from looking at it, you probably won't need to do that even. Just make flat-disc that fits ID of muffler outlet. Cut hole in centre for tube of correct size and length to go down and join with centre tube. Weld tube to end-cap. Then insert end-cap to muffler outlet.
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Old November 8th, 2018, 03:02 PM   #24
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The baffle tubes in mine are loose indicating to me the spot welds on the back side are broken so probably next week Iíll cut the rear weld fill in the four holes where there used to be rivets weld baffle tube to the rear plate re align and re weld back together. Could be interesting it may just fix it.
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