Thanks! That muffler took 3 good days to make. Mainly because I had to 'make' everything. The quadsport was easier.... I just cut down a large driveshaft and made use of tube I had already.

My stock muffler used to fall off all the time. I don't remember what the problem was, but I suspect it didn't have the right bolts or enough of them.















This was the sensible thing to do. Nice straight shot of the same size tube from beginning to end. No megaphones or bottlenecks. Driveshafts are light chromoly that is strong enough to contain the sound (sound = pressure). Being perfectly round helps it be strong. The bigger you go, the quieter it will be, which is why my 300 muffler is so big.

I didn't like any of the aftermarket mufflers. They're either megaphones or very thin and sound tinny like a tin can.

 

Yeah, jb weld isn't all that. It works sorta, but oil still comes out. I glued a couple rods together with jb weld. It didn't even take the force of breaking a toothpick to snap it apart. Its much more like glue than weld. That's for sure. It kinda reminds me of bondo.

Poolgod posted this a few years ago. Dura Fix Aluminum Welding Aluminum Brazing Aluminum Soldering & Repair Rod Always wanted to try it. Hopefully I won't have to lol.

 

you can get aluminum brazing rod from a local tractor supply or welding shop but you need it hot and a normal torch cant do it. you could also try lead which flows easy with heat and would hold up against oil. i am making my own chain gaurd and having my case fixed. best way to do it.

randy those mufflers you make look good man.

 

Thanks nate! Designing and building is what I like to do.

The best way I found to guard my chain is to make sure it never comes off. So I did this:





The chain has never come off since I installed that and I run it loose! And its a plain ole chain... not an oring or xring.

 

i may have to make something like that. sounds like it works great for you. also where my bolt hold on my swing arm the right side frame hole is a little worn out and if i pick up on the back bar i can make it move around. is there and easy fix for the frame?

 

None that I know off. I've heard of some welding a washer over the egg shaped hole. Or you could drill the hole bigger and put some tube over the bolt. I would use a new bolt too. They are expensive.... like $30... for a bolt. But....

 

Got my muffler bent back straight enough to re-attach using a vice with a piece of rebar held in it, some elbow grease, and a mini sledge.
Before:


After:



Also got everything all cleaned up, threw it up on jack stands, topped off the oil, took off the skid plate and inspected for leaks while i ran the engine for about 20 mins. I couldnt find anything other than a few small weeps i already knew about... not enough to lose a quart in a couple hours of riding. The only thing i can figure is it was puking the oil out at high revs while i was WFO down the road for prolonged periods of time. Ive heard that can happen if you run the wrong type of oil. I had been topping it off with 15w40 Delvac which was all i had around, so i drained the oil and replaced it with 10w40 as per the manual, and we will see if that was the prob. I think it was something to do with too heavy of oil, or maybe the wrong type of formulation that would foam up... cant remember exactly what it was i read or where i read it, we will see what happens, cause i cant find any real leaks.

also, here is a pic next to an 850 Sportsman... he could hardly keep up in the woods... wonder why? lol

 

Yeah that big hog hasn't a shot of keeping up lol.

Pretty good job on the muffler. Pretty soon you'll be making custom gas tanks for harleys

Everyone was trying to talk me out of boring my king. I'm like "I thought you said it was a no-brainer?". The reply was "Yeah, but that's before I saw how good it runs. No need to tear down a perfectly good motor! It has plenty of power!". I disagree. I can't even hit 40mph by the corner of the garage. Usually I'm close to revved out in 5th gear on the quadsport by that point. I mean... I have to be able to leave all those small jeeps behind right lol. So the jug went out the door. Get it back next week hopefully. It'll be 10.325:1 at 288cc with a 250s cam and 650lbs of ***!

So, if its puking oil, where would it be coming from? Are you sure it lost a quart? That sight window can play tricks on you. When I get to the mtns, it looks like I'm bone dry. If I add a quart, then I have too much when I get home.

 

after sitting all night there was no oil visible in the sight gauge, and there was oil all over the back of the eng/trans area and swingarm parts. I assume it was coming out one of the breathers. i'll just have to keep a closer eye on it now. The same thing happened to my father in law on his motorcycle. He just got done building a 1969 Honda CB750 and he put 20w racing oil in it and everything looked and ran good in the shop, as soon as we got out on the highway there was oil all over the place. Coincidently, he just bought a 250 quad runner, looks like we will be sharing a clymer manual lol

 

I'm lost. How does oil make it out of the breather on the top of the engine by sitting all night? lol. And if its coming out of the breather at all, I would think there is significant blowby around the piston rings to blow the oil out. And even then... how does oil make it to the top of the engine like that in enough concentration to be blow out by the quart? Of all the funny things I've seen an engine do, I've never seen this one lol. I have a feeling I'm about to learn something lol

I used to have a 750-4 when I was a teen. I ran 20w50 because I didn't know any better. I didn't have oil spewing out everywhere, but I did spin a cam bearing. 20w oil is too thick.