Exhaust muffler rattle??

[Budweiser]

Guys, my 06 Attak with 16,000 miles has developed a rattle in the MUFFLER. This is not donut related. Been there, still doing that every year! I've taken the heat shield off and it still rattles. Sounds like its coming from inside the muffler. Still has that awesome Apex sound but with a rattle. Sound will vary with rpms, sometimes disappears for a second. Nothing else is loose back there.

I believe something inside the muffler has come loose. A baffle. Does this make sense? Anyone else have this at these miles?

Dealer cost for a new muffler is $544.96. Ouch! I've searched and found that people are "gutting" their exhausts. I'm not interested in doing that but maybe I can cut the top of the exhaust off and remove the rattling piece and then weld the top piece back on? Thoughts??

Thanks for the opinions!

 

[Wisconsin]

You can always cut it open re-weld the piece that broke off....or faint when you realize that it's something from inside the motor that got caught in the muffler when it passed through!

I gutted mine and no problems, but if you want it as quiet as possible, I'd try to re-weld it. Open it up and let us know what was rattling....you've either got to fix it or buy a new muffler. Probably find some stock mufflers on the forum for sale from people that bought aftermarket exhaust.

 

[steiner]

Open up the can and either weld up the piece that is rattling around or just remove it and button up the can again.

 

[Hammer 1]

I had one of my tunnel proectors come loose. The rivits that hold them on started to wear and would rattle like cazy.

 

[Yamadogger]

If it's definitely inside your muffler then follow the instuctions in the attached post and just skip the steps about removing the internals from your muffler. Find whatever is rattling and weld it up. It's a quick job if you have a welder and a small amount of mechanical skills.
http://www.ty4stroke.com/viewtopic.php?t=46386&highlight=apex+exhaust+gutting+pics

 

[NY AttakGT]

I had one of my tunnel proectors come loose. The rivits that hold them on started to wear and would rattle like cazy.

X2. My tunnel protectors were loose on both sides, in back, under the exhaust. That and also one of the rivits that secures the rear coolant x-over tube.

 

[redrx1rkt]

Budweiser - how the hell did you get 16,000 miles riding in the same area (approximately) that I do???

 

[Attack gt]

I did the muffler mod and I cant see that anything could come loose? Everything in there is pretty solid. When I cut mine open and gutted it, I took pics and have seen pics on tty some were? It sounds great and is not unbearably loud but if you dont care to cut it open, then a cheap alternative would be to replace it with a used one. E-bay has them pretty cheap like 100 dollars. Hope this helps!

 

[Budweiser]

Thanks for all the replies! Its not the tunnel protectors, they have come loose before and I reriveted them. They are rock solid now.

I think I'll go with opening it up and seeing what's rattling. Worse thing that could happen is I have to buy a used one.

redrx1rkt - I ride in Quebec at least once a year. Just put 1300 miles on in 4.5 days up there!

 

[redrx1rkt]

Ah yes. The miles roll on pretty quick up there. I haven't ridden there since 2005. I miss it. However, with a camp in Oswego County and lots of riding opportunities stateside...plus gas and permit costs...its hard to justify anymore. I once put 900+ in 3.5 days myself! My only 4,000+ mile season came with lots of help from Quebec.

 

[Budweiser]

Update on my issue:

Rode the sled on a overnight trip. About 10 miles into it it gets louder. No more rattle. Sled ran fine so I tried not to worry about it! Took it apart yesterday and found a large, 1 by 2 inch missing piece out where the muffler piece joins the Y pipes. And cracked all over in that area. I thiink the rattle I heard was when it was cracked and when it got louder was when the piece fell out. Its all welded up tight now.

The good thing about working nights. Took it apart Monday, brought it to work Tuesday night to get welded, will be back together Tuesday day! Riding Wednesday!