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Discussion Starter #1
so I got a hole in my muffler at the back un the bottom, it's annoyingly loud I prefer keep things quiet any suggestions on a replacement or should I just weld a plate on it? I found it kind of loud to begin with stock but maybe that's just me.

2006 400xt max
 

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if it were me i would just weld a patch over it... but i have a welder and everything to do that... If you have to pay for the repair it may be just as expensive to order a new
 

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Discussion Starter #3
I JB welded a patch on as a temp. If fell off of course but I didn't grind it down much. I was going to weld it in September once I'm back in the shop.

Was hoping for another option like use a 800 muffler or something. Not sure if they are bigger.

A buddy came over with his 1000 and wow it was so quite.
 

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Lots of owners of those older bikes report issues with the factory muffler, and unfortunately, there's not much in the way of "affordable" plug-n-play replacements. I'm aware of some mufflers that Tractor Supply has/sells, that fellas with little 300cc Fourtrax's (like my boys bike) use a lot. Think the model FO-4 or FO-14, one's baffled, ones not, have the right size inlet to weld into place on your bike.

Regardless, there's going to have to be some welding/customization done, I'm afraid. Let us know if you do come across something that's for that application/bolt-on.
 
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Would take allot of mods to get a 800 or bigger to fit as they are a different design and placement. Would be better off to use the suggestion above and make a replacement. They can be had fairly cheep so if you screw up no huge loss
 

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I just welded mine up yesterday. I did post on it. Took a little time but quiet now. Also had to fix my heat shield mount so no rattle from that either. I had some 4" and 3" exhaust pipe pieces I used for the patches. worked good as they are close to the right arc. Plan on 100% bigger then you think. Once you see a hole, it will be soft around it for quite a ways before finding some solid metal to weld to.
 
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