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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.

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Old 14 Sep 2009
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need help with muffler previous owner cut end off

Hello is there somthing i can do for this instead of buying a new one the previous owner cut out the end piece of muffler on my xt 550 now its really loud and backfires alot he cut it out basically 3 inch hole now and i can see the baffles inside is there a piece i can buy to put on the end like a silincer thanks
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Old 14 Sep 2009
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Sure , how are you at oxy -acetylene welding or brazing ? Know anybody who welds? A bit of fabrication will get your problem solved. Remove muffler from bike. Clean out the soot or rust scale from the end.
Just find a piece of thin plate steel and cut out a nice circular or oval plate.I assume the baffles inside the muffler are still attached to their supports , so forget them. Hold the flat piece against the muffler stub and scribe a line where they contact . Now comes the fabbing part. Use a hammer and some sort of anvil and start whacking away to bend the flange area outside the scribed line into a bend which either will make the piece fit inside or cap over the muffler stub. You may have to make short relief hacksaw cuts in the flange to get it to work.
When you get this all done, determine what size diameter the original exhaust hole is supposed to be and find a nice short stub of steel pipe the same size. drill a hole in the plate so that the stub is a snug fit.
Get out your welding kit , or go to said friend- or a pro weld shop, and have the plot put together.
If you do all the fabbing you will save loads on what you would pay for a weld shop to do it all, and just paying for the welding will also be lots cheaper than a whole new muffler. And it will work just fine. Spray some black heat resistant paint on and reasemble muffler onto bike./
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Old 15 Sep 2009
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The std XT550 mufflers were quite restrictive causing a lack of top-end power, so that may be why the end has been cut out.
If you can afford it I would recommend an aftermarket straight-through type muffler(good sound & good top-end power).
Bob
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