Silencer modification on my 500R

[Billy Golightly]

After talking to some different people and doing some research on my own I've decided the main reason the 500 over heated like it did and melted was from excess EGTs...caused by a to small of stinger tube (the piece of pipe that goes from the expansion chamber into the muffler) diameter which was restricting the outflow of the exhaust and causing an excess build up of heat inside the motor that could not escape. I had used a normal 250cc motor size tube, which is 1 1/8 OD size, I can't recall the exact dimensions of the inside but its just a hair over one inch if I recall correctly. I'm upgrading to 1 1/4 OD diameter tube, which is about 1.125in diameter inside. Running big out of the exhaust chamber and then back to a downsize on the silencer again doesn't really make any sense, so I took the silencer apart. I also found that it didn't have a drop of packing in it which seemed odd to me :lol:

First things first, comparison picture of the old silencer core and my "new one" I'm making drilling lots of large diameter holes. Some expanded metal rolled up woulda been better but I'm fresh out at the moment.

http://i150.photobucket.com/albums/s100/HondaATC/Silencer%20Mods/P1010007.jpg


And next up is a close up of my welds with the new inner "screen"...I like to look at my own work an awful lot for some reason? :lol:

http://i150.photobucket.com/albums/s100/HondaATC/Silencer%20Mods/P1010008Large.jpg

And heres a pic from the ends to show the diameter differences a little bit better.

http://i150.photobucket.com/albums/s100/HondaATC/Silencer%20Mods/P1010010Large.jpg

This is the back of it, I haven't bent up and welded on the new 1 1/4 tube yet, this is the old stock 250 sized tube.

http://i150.photobucket.com/albums/s100/HondaATC/Silencer%20Mods/P1010012Large.jpg

Empty canister with both ends removed...

http://i150.photobucket.com/albums/s100/HondaATC/Silencer%20Mods/P1010015Large.jpg

End cap now, which will be modded also and I think I'm gonna have an LRD style turn down on it perhaps. First pic, shows the side that goes in.

http://i150.photobucket.com/albums/s100/HondaATC/Silencer%20Mods/P1010017Large.jpg
http://i150.photobucket.com/albums/s100/HondaATC/Silencer%20Mods/P1010020Large.jpg


And last but not least...current pics of the 500 in my own mad dash to re-assemble before TF:

http://i150.photobucket.com/albums/s100/HondaATC/Silencer%20Mods/P1010022Large.jpg
http://i150.photobucket.com/albums/s100/HondaATC/Silencer%20Mods/P1010024Large.jpg

Thanks for lookin.

[Daddio]

Billy just in case you didn't see this when it was posted. Pretty good info.

http://www.3wheelerworldforums.com/showthread.php?t=64590

[Kintore]

hmm interesting billy

I hope your painting/PC that frame! lol

[Billy Golightly]

I plan to but it probably aint gonna happen before TF. Its got a protective coating called "OSPHO" on it now.

[Kintore]

Just some honda red look a like edog spray bomb will satisfy me lol

[Dirtcrasher]

Looking good Billy, I love TIG welding!!! Not that I know how, but I will someday :lol:

[250rfan]

Looking good Billy, I love TIG welding!!! Not that I know how, but I will someday :lol:


:Bounce,,, i agree, your welding skills have definately improved since the header pipe fabrication,,, the trick with tig is keep the amps as high as you can, i know this would have been tricky on the thin walled header pipe.:) :)

High amps and speed, and you'll soon have quality beeds......:w00t: