1986 250SX exhaust muffler replacement with DG

[dansvan]

Hello all. I decided to take a chance and try a muffler from a different bike on my SX. I picked up a DG unit for a 1988 trx250r. It was cheap off of ebay and I figured I could use it on any number of projects. The trike is a work in progress, with all my attention going to the 200x right now. Here's a few pics.

Stock muffler.
http://www.supermotors.net/getfile/509387/fullsize/stock-muffler.jpg

Again.
http://www.supermotors.net/getfile/509388/fullsize/stock-muffler-2.jpg

DG installed to mount and pipe sectioned for re-weld.
http://www.supermotors.net/getfile/509389/fullsize/piece-missing.jpg

Another pic.
http://www.supermotors.net/getfile/509390/fullsize/cut-made-1.jpg

Positioning sectioned piece for re-welding.
http://www.supermotors.net/getfile/509392/fullsize/cut-made.jpg

[dansvan]

Weld made.
http://www.supermotors.net/getfile/509393/fullsize/welded.jpg

Another pic.
http://www.supermotors.net/getfile/509394/fullsize/welded-1.jpg

Installed
http://www.supermotors.net/getfile/509395/fullsize/dg-iinstalled.jpg

Another install shot.
http://www.supermotors.net/getfile/509396/fullsize/dg-installed2.jpg


Install was easy. I like the look. Trike is loud. Not super bad, but slightly louder than I like for a 4 stroke. Neighbor loves it. I'm going to try their quieter core insert. More power? Don't know yet. Still doing the 350X carb. swap and installing new swinger bearings. I'll let you know.

[gladiator mice]

i just picked up a 85 250sx. iv done the research over and over and still keep reading that 250sx aftermarket exhausts are out of the loop. your idea and process is amazing, the welds look strong too. might find a cheap dg or cobra slip on pipe and attack the old muffler like you did above. thumbs up to you.

[dougspcs]

Too bad you hacked up the OEM muffler pipe..you could have gotten a pretty penny for it if still solid.


i just picked up a 85 250sx. iv done the research over and over and still keep reading that 250sx aftermarket exhausts are out of the loop.

BTW the aftermarket 250ES exhaust system will fit the 250SX direct bolt-on, you just have to cut the mid-pipe support bracket from the frame with a grinder. I did it with my 250SX last year..

I believe it sometimes sells under the brand name Kimpex..

http://www.ebay.com/itm/ATC-250ES-250-BIG-RED-SLIP-ON-EXHAUST-MUFFLER-85-87-Z-/400264732079?pt=Motors_ATV_Parts_Accessories&hash=item5d31a31daf&vxp=mtr