Ahhhhhhhhhh.................. Welcome to the world of the stainless steel exhaust on the Foreman 400. They ALL do that eventually. Honda went to stainless stell because so many mufflers were rusting out and eliminated the rust problem but made another. The rear baffle comes loose in em. If you can find someone to weld the back of the muffler you can cut into it and remove the old one , then weld the back of the muffler back on. I will still be a touch louder, just without the rattle. It will also more than likely start backfiring when you let off the throttle once in a while. Prob not that often but that is a classic symptom that accompanies a loose baffle. I have had mine backfire 5 times on a 20 mile ride and a few weeks later backfire once on an 80 mile ride, so it will not always do it.
I cut mine open at the center and welded the baffles back in place. The baffles have an edge on them that was originally tacked to the canister in 3 places. To get at the welds that were too far into the can to weld I just drilled a series of holes around the canister where the baffle plates would sit. Then I positioned the plates and welded them in place thru the holes. Then I welded the muffler back together. Works good as new and the backfire disappeared.
Hey, that is a great idea on how to weld the baffle back in. I knew it was too far back to weld the normal way but never thought of the hole drilling idea! That is what is great about these forums, what one does not think of, someone else does and everyone benefits.
ok update my dad (the welder) cant be bothered to mend it and ses he will get a new honda one but this gives me the perfect opertunity to get a supertrapp idsx pipe, is it any good??? can i run it without jetting?? all i want it for is as a muffler but i like the idsx. so any help will be useful.
ok update. my dad (the welder) cant be bothered to mend it and ses he will get a new honda one but this gives me the perfect opertunity to get a supertrapp idsx pipe, is it any good??? can i run it without jetting?? all i want it for is as a muffler but i like the idsx. so any help will be useful.
edit: can u recomed any other types, i cant find a HMF for the 400
sorry double post
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