I just purchased a 1986 trx200sx. I was wondering about this atv's exhaust. It has stock exhaust on it, but the baffle, tail pipe, cap, is missing from my stock exhaust pipe. So bascially there is a large hole for the exhuast to come out, and no end cap on it. The guy I bought it from told me that those old bikes were known for blowing out the end caps? I was just wondering if anyone knows where I could get a end cap/tail pipe, and or make one for my bike. I thank you in advance for any help or guidence you can give me.

 

Check the local salvage yard for starters. The piece cant be bought new,...only as a muffler assembly.

However, the long screw in type mufflers for an 8HP Briggs still seem to be a good choice in patching old exhausts. Cost less than 10 bucks and all you need is someone who can weld thin metal have it put in place for ya and weld it in. Done it dozens of times over the years on numerous machines myself.
It's not a permanent fix ofcourse and usually only lasts a couple seasons until it to burns out, but it's better than $250+ for a new exhaust system and it does not harm your engine or require you to rejet the carburetor whatsoever unless you jetted it after the core was removed.

By the way, what I explain above is for the Briggs muffler to be welded into the place of where the end cap was removed. Slide the muffler in and weld a bead around it on the outside back flush so that it looks as it did stock. Dont weld the Briggs muffler directly to the header pipe of the ATV or it would be doing very well to last a single ride.

 

thank you very much for the response. On this webstie, http://www.jackssmallengines.com/bsmuf.cfm are you talking about part number 105007 and or 105106? Also, would the screw end go into the the existing muffler? Lastly, is this method too restrictive, or is it about the same as it would be for the stock exhaust. Thank you for your response, and it sounds like a great idea!!

 

If you are still looking I have a stock muffler and head pipe if you want it. Otherwise you can pick up cobra exhaust off ebay for $150 or less on ebay. Let me know!

 

It's not too restrictive on anything I have put them on.
Besides, you ever see the add on stalker system that some hunters use on their quads? If that's not restrictive, I dont know what is short of sealing the entire exit.

The srew in portion of the muffler goes into the muffler of the ATV but does not need to be attached. It's welded from the outside on the tail end to hold it center.

The aftermarket pipes,...even what they refer to as "quiet series" will never be as quite as the factory setup was. Dealt with them all. Goes for Cobra and Supertrapp alike.

The stock system that STANG302 has might be something you want to look into.

 

I forgot to mention it is off my 200sx and in good condition.

 

stang302, how do i get in contact with you about this muffler? Please let me know. Thank you.

Andy