Dual Mufflers

I decidied to do this muffler conversion simply as something different to do; I think it looks fine and there is a noticeable difference in power delivery not that I was looking for more speed! The acceleration from bottom to top end is more rapid; probably due to the less restriction in the mufflers so the gasses flow a lot quicker. It was necessary to richen the fuel mixture a tad.

The mufflers and linking pipe I bought off a chap who'd replaced his 2006 CRF250R system with a Pro-Circuit set up.

I no longer use the dual mufflers having gone back to the original muffler. The duals you have to repack every so often.

Click each picture to see a larger version.

2006 CRF250R system.

The newer style muffler above I'd bought brand new and decided not to cut it up and as I still had the old original 1985 muffler, I used that one. After measuring, I cut the front section off it (where it joins the header pipes) and cut the same length off the CRF250R linking pipe. After welding the bits together, some black heat paint and a couple of aluminium hangers for the mufflers to mount to the frame all that was left was to mount it and fire the old girl up.

The piece I cut off the linking pipe to use as a guide for the amount to cut off the 1985 XR250 muffler.

Linking pipe with 1985 section welded on and then painted.

All done and ready to attach.

A couple of weeks later I replaced the packing in the mufflers. To do this you only need to drill out the rivets at the linking pipe end of the mufflers. Then using a plumbers blow-torch, heat up the area around the rivets you took out and using a twist/pull motion remove the muffler casing.

Here you can see the sealer that you'd be heating up.

View looking towards the exit end of the muffler.

The new muffler packing. In total there's 3 sections for each muffler.

www.xr250.co.uk

www.hondaxr250.com