check it out i have been talkin to some atc200 owners over at 3wheelerworld about an exhaust for my 84trx200 they suggested to find a universal pipe and weld it on to my head pipe i would need an inlet size of about 1.3inches i couldent find 1 ne where the best i found was 1.5 and 1 3/4 do u suggest tryin to weld it on? or maybe i could use a dg rcm pipe from a 84atc200es?

 

I don't see a big deal with making a sleeve to compensate for the difference between the two pipe sizes. What you want to do is make an adapter to fit the universal muffler to the headpipe. Clamp on both ends. Forget the welding. No sense in ruining an otherwise headpipe because that universal muffler, like any other, is only going to last for so long.

What I have done in the past on many exhaust systems is use a cannister type muffler that is used on power equipment engine like riding mowers, and insert them into the back of the stock exhaust silncer housing and putting a few tack welds on the outside to hold it in place. The sound is close to stock and works very well compared to other options. These mufflers will require replacing every couple of years, but usually can be bought for under $10.00 and the tack welds are very easy to grind off for removal. This trick will only work though if your stock muffler isn't rusted through underneath. If it is, you will be better off going with your suggestion.