Honda fourtrax issues

DRZRon1

DRZRon1

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After checking everything else I could think of, I finally cut the muffler off the exhaust pipe...the exhaust pipe and muffler are one piece. The issue is that the muffler is blocked on the inside. So I am going to most likely look for a muffler to replace it.
Any chance to take a portaband, cut off wheel, etc and cut an end off and see what’s cooking inside ?
 
C

Cowman

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I used a cutoff wheel to cut around the circumference of the inlet end of the muffler, but it would not come apart. Appears that internal perforated tube is connected somewhere inside. I guess I could cut completely through. Funny thing is, nothing came out when I whacked it on each end while holding vertically, nor does anything rattle inside when I shake it.
 
Farmer

Farmer

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Yeah exhaust issues can drive you nuts... I once rebuilt a CR250 thinking the two stroke was tired. Turned out the silencer core rotted and let the packing fall to block the hole. Was pulling my hair until a buddy put his hand over the exhaust and said....there's nothin coming out. I was pretty green back then. Good news was that bike ran fast after the new rings and piston. If I skipped race day, my buddies were fighting over who got to borrow it.
 
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Cowman

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I ended up ordering the Caltric muffler/exhaust pipe for it. But there is a good chance I will end up just cutting the new muffler off the pipe and attaching it to my existing pipe as it seems to be in good condition. I have soaked the two exhaust header bolts/nuts with a penetrating oil for a few days, but they don't seem inclined to turn loose, and I really don't want a broken exhaust header stud. I have a piece of tubing that is just the right size to slip over the ends of the exhaust tube and the muffler where they will join, and since I have already cut the old muffler off, I think that is the route I will go. I can then weld that in place and still have my hanging and shield brackets.
 
ChadD

ChadD

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I ended up ordering the Caltric muffler/exhaust pipe for it. But there is a good chance I will end up just cutting the new muffler off the pipe and attaching it to my existing pipe as it seems to be in good condition. I have soaked the two exhaust header bolts/nuts with a penetrating oil for a few days, but they don't seem inclined to turn loose, and I really don't want a broken exhaust header stud. I have a piece of tubing that is just the right size to slip over the ends of the exhaust tube and the muffler where they will join, and since I have already cut the old muffler off, I think that is the route I will go. I can then weld that in place and still have my hanging and shield brackets.



This stuff works pretty good. Local farmers recommended it to me. They use it when working on stuff in the fields 😎👍
 
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Cowman

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It's been soaking in Kroil for several days. That is pretty good stuff that I have had a lot of luck with. But may have to give what you show a try.
 
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DRZRon1

DRZRon1

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It's been soaking in Kroil for several days. That is pretty good stuff that I have had a lot of luck with. But may have to give what you show a try.
kroil/little bit of heat and always try to tighten a little before loosen if possible
 
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Hello_Darkness

Hello_Darkness

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It's been soaking in Kroil for several days. That is pretty good stuff that I have had a lot of luck with. But may have to give what you show a try.

Generally the studs cone out of the head instead of breaking, atleast in my experience.

It's rare that I've broken a stud, usually it's on Goldwings where they use tapered studs to fit a smaller nut due to space.
 
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