Let's touch on a broad topic correct selection exhaust system. Motorcycle exhaust system tuning.
To breathe freely, we need to not only inhale deeply, but also exhale freely. There is no point in inhaling deeply when exhaling poorly.
I propose to divide the exhaust into several components:
Collector.
Catalyst.
Power boost valve.
Can (Slip On).
The first and main thing is the fight against weight. A standard exhaust weighs between 10 and 15 kg. The tuned muffler with racing manifold assembly weighs up to 5 kg. And reducing weight by 5-10 kg is a very serious tuning, which can be achieved for relatively little money. Now let's move on to the characteristics. There are many elements in the standard exhaust that slow down the free flow exhaust gases. Catalyst... we, of course, are not against saving the earth and the environment, but on the other hand, it’s a shame when you are passed over a meter before the finish line. Therefore, we remove the catalyst immediately and mercilessly. Next comes the power boost valve. This is a damper with an electric motor that covers the exhaust pipe, slowing down the flow of gases, thereby forcing the engine to work under low load, producing more power in an “inconvenient” speed range.
By removing the valve, we get an even greater failure at low engine speeds. Considering that our motorcycle already has zero filter, it turns out that the motorcycle will not ride at all at the bottom and that’s not all. The rule is simple: the freer the flow of gases, the faster the motorcycle is. high speed and even worse at low levels. That is, the overall range of work is shifting upward, which is why we are tuning the equipment. Not everything is so sad, but first things first. Let's move on to the bank. A little lyrical digression. Often on motorcycles they change the can (Slip it), that is, the range of operation changes slightly upward, very slightly, but it is considered tuning :) In fact, just the sound changes and we are not talking about any gain, it’s like driving around the city on slicks 🙂 Pseudo-sports motorcycle. But in our case, all braking elements of the exhaust system were replaced. Therefore, replacing the can is no longer a question. By replacing the muffler, we increase the sound pressure (let me remind you that on most European tracks there is a limit of 95 decibels on the maximum noise level; with a very loud exhaust you can get a disqual) But most famous manufacturers make cans with a noise level limit. But in any case, the movement of exhaust gases is accelerated compared to a standard “can”.
So we shifted the power distribution even further upward, now the motorcycle doesn’t ride at all at the bottom, most likely at the top too, but much better than the standard. This completes the replacement of the exhaust system. If everything is chosen correctly, then the motorcycle should stop moving normally and get a bunch of dips in the ranges. Moreover, if you drive like this, there is a chance to change the engine with burnt valves or pistons due to an incorrect mixture.
Instructions on how to independently give a new and beautiful look to an old scooter muffler, and at the same time make it quieter.
Point 1. For work we need.
Materials:
A piece of thin stainless steel, 0.4-1 mm thick.
A piece of fabric, rolled heat-resistant sound absorber, ~5 mm thick.
Tools:
Semi-automatic welding.
Grinder with a thin disc of 1 mm.
Point 2. Reasons.
Over time, even the most famous manufacturers of motorcycles, like Honda in this case, completely clog the muffler with exhaust deposits, after which the engine does not start and there are only two options: buy a new Chinese muffler or dismantle and clean the old one.
But since the Chinese muffler completely lacks a wave reverse resonance system, that is, it is just an empty can, also very thin, and as a result for two-stroke engine, this is a loss of power up to 50% and as a result the scooter completely stops riding!
When disassembling the muffler, it is necessary to remove the internal sound absorber of the fiberglass body, after which the sound of the operating scooter becomes louder and more obnoxious (ringing), that is, the body can itself rings and resonates, and appearance no longer as neat as before.
That's why, self installation An additional decorative housing with an additional sound absorber will be very useful.
Point 3. Manufacturing and installation.
Unscrew and remove the muffler.
We measure the circumference of the muffler can and the length between the welds.
To the resulting circumference dimensions we add 2-3 cm for overlap, and to the width 2 cm for bends.
We cut out a design rectangle from thin stainless steel.
On both sides of the wide side we make bends of 5-6 mm.
Polish the surface with GOE paste.
Use a thin disk to make cuts in 5 mm increments.
We remove sharp edges and burrs.
Using the resulting dimensions, we cut out a piece of noise absorber (for example, asbestos weave, fiberglass, etc.) so that it fits tightly inside between the folds.
We wrap it around the muffler can so that the joint is on the back side.
For ease of welding, we secure it with clamps or other fasteners (for example, rubber rings).
We do spot welding.
A motorcycle muffler is a device that weakens the sound of the engine. Mufflers are needed not so much to reduce noise as to change the timbre. And high-frequency sounds have a more unpleasant effect on the human psyche and ear than low tones.
Many people associate the roar of sports motorcycles with a muffler. And they believe that filling the muffler can reduce the power of the car. But that's not true. When replacing or modifying a muffler, only a small amount of horsepower is lost.
There is an intake and exhaust silencer. And scientific research has proven that if you choose the right basic elements, you can improve the filling of the cylinder. Such mufflers are called resonant mufflers.
Noise suppression is carried out by the part of the muffler located behind the first partition, and it consists of an acoustic filter. These filters are on sports motorcycles made more simply, since in sports motorcycles a higher noise level is allowed.
When deciding to remake a muffler, you need to remember the following. Sometimes, when improving one part, you have to sacrifice the quality of another. No one has yet succeeded in creating a universal motorcycle.
Manufacturers recommend using factory mufflers for your motorcycle. The muffler cavity becomes covered with carbon deposits, which can close the acoustic filter channels. Therefore, the cavity of the device must be cleaned regularly. The resulting carbon deposits prevent the exhaust gases from escaping, and engine power is reduced. After every five to ten thousand kilometers, mufflers need to be cleaned.
The original mufflers are quite quiet and good. Their disadvantage can be considered their heavy weight and size. Many people consider their high price to be a disadvantage. Silencers are manufactured by many companies, and you can use a non-original muffler if you wish. Most often these are open mufflers. In them traffic fumes exit the engine without any obstruction. But they make a lot of noise.
Those who love the loud roar of motorcycles can buy the cheapest muffler, which does not muffle anything. But if the roar of the motorcycle does not suit you, then you will have to buy an expensive option.
These mufflers differ in design and material of manufacture. There are four types:
- Titanium. He is considered the best. It's light, looks nice, and doesn't get too hot.
- Aluminum. Light enough. It looks worse than titanium, but there is a drawback. You can get seriously burned.
- Carbon. Looks nice, light and cool. But its significant drawback is that even with vibrations it can crumble.
- Stainless steel. Strong and heavy, but very hot.
Each type of muffler has its own advantages and disadvantages. Therefore, you need to choose for yourself.
You can buy a direct-flow muffler in any specialized stores. They are usually of interest to young motorcyclists who dream of high speeds. But real bikers don't buy stickers famous brands. They do everything they need with their own hands.
If you want to enter the world for real men, you need to make a direct-flow muffler with your own hands. When riding at normal speed, its noise will not be different from other motorcycles. But as the speed increases, the characteristic rumble of the engine appears.
What do I need to do?
- Take a piece of pipe that has a diameter of 60 mm and cut it in half. First, one part is processed and a flange is welded in the middle. The outer part does not change. This is the inlet pipe. In half of the pipe, which is located in the muffler, you need to drill a large number of holes using an electric drill. You need to use a 5-6 mm drill. Recess the flange with a ten-millimeter tip into a pipe with a diameter of 100 mm and weld it.
- We are preparing the second pipe. Weld a flange to the second section of pipe. It should be 80 mm from the edge. This part of the pipe will be inserted into the muffler.
- Carefully lay mineral wool insulation into a pipe with a diameter of 100 mm. This is to combat noise reduction. To do this, roll the cotton wool along the diameter of the pipe and push it to the opposite side.
- Roll up the mesh and lower it inside the insulation that was inserted into the pipe. The mesh should fit onto the pipe with holes.
- Now you need to insert the flange with the pipe, which you prepared in advance, into the pipe with the short end. It needs to be recessed to a depth of 10 mm and welded.
- You can cut off the fastening elements from the old muffler and transfer them to the direct-flow muffler by welding them.
Why do motorcyclists need forward flow on a motorcycle?
The exhaust system is designed to perform several tasks. Exhaust gases are removed. The exhaust gases better fill the engine cylinders. And dampens the noise. The spent mixture flies out of the cylinders with very high speed and therefore a loud noise is created. It is the muffler that reduces the noise of exhaust gases due to the obstacles installed in it.
A straight-through muffler simply does not have baffles that reduce noise. In this case, exhaust gases exit without obstruction, and engine power increases. Therefore, the noise on such motorcycles is like a roar.
A direct-flow muffler or direct-flow muffler on a motorcycle produces a peculiar engine roar and is not accepted by many people. It is believed that motorcycles with such a muffler disturb people and pollute the atmosphere.
Motorcyclists promoting quiet ride in the city, they do not accept direct-flow mufflers. But experienced bikers are sure that forward flow is not only passive safety, but even active safety on the roads. How? The fact that you can indicate your location in the traffic.
Sometimes it is difficult to show some drivers even with a signal or headlights that you are nearby. And only the roar of the muffler helps to do this. And it happens that the sound of the muffler stops the driver from a careless maneuver that could lead to an accident.
Hello.
After several loud cries of “curvaaa!!!” with the motorcycle spinning into tree branches, the muffler on the poor TM EN 300... was dented :) I had to make a new one.
I could never do this kind of work. With the exception of minor manipulations, such as burning the flute and trips for materials, the new muffler bank was completely made by Oleg, for which another huge thank you to him!
A muffler is one of the most common motorcycle tuning options. A logical question: why, in addition to simply saving money, bother making a copy of a stock silencer when you can order a tuned one, at the same time slightly dampening the exhaust. The fact is that tuning the exhaust on two-stroke motorcycles must begin, first of all, with the resonator. And then, to the resonator, which are selected for the desired operating speed range, select a muffler can. Or not to select it, since on two-stroke engines it does not have the same effect as on 4t. Therefore, ordering a tuned muffler can without tuning the resonator makes no sense, and ordering a stock one is doubly pointless. There is one more factor in order not to order FMF, Yoshka and similar products: there is already so much stupidity in a two-stroke three hundred that I, for example, will not need to increase it additionally for many more years :)
The original muffler on the TM EN 300 is made of foil, it wrinkles well, bends after another fall, and begins to catch the wheel when landing from jumps, when the suspension compresses - and wears through to holes!
Therefore, having sacrificed a little to save on weight, I had to do new muffler made of aluminum pipe 3 mm thick.
The pipe, however, was found with a diameter of only 100 mm, while in order to maintain the original proportions, the diameter of the pipe should have been 90 mm.
At the same time, I burned the flute. As it turned out, you don’t even need a burner for this; a hair dryer at 400 degrees will do just fine.
In addition to saving the weight of the motorcycle, not a single manufacturer will install mufflers with a 3 mm wall on their motorcycles, or at least with 3 mm mounting brackets to the subframe, because then this can will never break in life, and the costs of materials will increase .
The neat flake weld will face down towards the ground and will not be noticeable. It's time to make a plug from a 3 mm aluminum sheet. Then a tube will be welded into it, which will center and secure the flute from the inside.
What is a muffler and what is it used for? The goal is to acquaint you not only with how to construct a homemade muffler for a scooter with your own hands, but also with the purpose of this important unit.
Two stroke and four stroke scooter
A scooter, as you know, can be with a two-stroke or a four-stroke engine. The operating principle of the entire exhaust system differs radically among analogues.
The muffler on a four-stroke scooter removes gases in a relatively shorter time, doing this with minimal noise. In addition, tuning the muffler in this case will be quite simple. On the other hand, in both cases, when carrying out tuning, it will be necessary to change the pipes.
For the muffler of a two-stroke scooter, selecting components that make it possible to carry out tuning will be much more difficult. The standard muffler itself for such scooters is more difficult to manufacture and configure.
The exhaust system of a two-stroke scooter works as follows. During the exhaust gas cleaning process, part of the power is returned to the engine. This happens at certain speeds and if you manage to implement this whole process by tuning, the scooter will be unrecognizable.
Can be installed on two stroke scooter high-quality and correctly tuned resonator. This will give a noticeable increase in dynamics up to a quarter. But in this case, it will be important to carry out professional settings of the entire power system.
Why do you need quality mufflers?
As you know, a certain amount of fuel combustion products accumulates in the cylinders of a moped engine. They must be thrown out and in this case it is the muffler that is responsible for this. In other words, this unit seems to smooth out the pulsations that are inevitable when combustion products are released at high speed.
The very design of the muffler, used not only on scooters and mopeds, but also on motorcycles and cars, implies a special exhaust system, which can be different, depending on what result the owner wants to get vehicle. For example, if the desire to improve the gas exhaust system is related to increasing the power of the scooter, a special type of muffler is required - a direct-flow muffler.
Direct flow type muffler
Installing this type of muffler will not only increase dynamic power, but will also significantly increase the noise emitted when gases escape. On the one hand, this is good, because this way you can attract the attention of other drivers, thereby increasing passive safety. As you know, drivers often large cars they complain that they don’t notice motorcyclists, and mopeds and scooters even more so.
Making such a muffler from scratch or using a method that involves tuning is not difficult, but you need to study many technical aspects.
Features of a straight-through muffler
The features of direct flow are as follows: exhaust gases are ejected outside the engine immediately, the cylinders power unit have time to fill with the fuel mixture in the optimal quantity.
I would like to remind all readers that at the moments of intake and exhaust, engine valves tend to open and close. Between these stages, a vacuum occurs, which allows the cylinders to be cleared of exhaust gases. As a result, free space is freed up, where it is supplied fuel mixture. It is easy to guess that the faster the cylinders are released from exhaustion, the faster they will be filled.
Thus, if you can ensure a faster exit of gases from the system, the performance and, as a result, the power of the scooter or moped will increase.
Cleaning the muffler
Before you start changing anything in the exhaust system, I would like to give one piece of advice. The power of the scooter is directly affected by the cleanliness of the muffler. If it were possible to see the exhaust in a cross-section of the muffler, the owner of the scooter would be very surprised. After a certain mileage, the scooter's dynamics decrease, and owners begin to look for the reasons for this, finding them in a complete rework of the standard muffler or its replacement.
The reason for the loss of power, meanwhile, may be hidden in the condition of the engine itself. This will help determine the specialist you should contact before tuning. But most common cause Loss of dynamics becomes soot, which clogs the muffler. In this case, it is recommended to carry out cleaning in three ways.
First method: mechanical
It involves cleaning the muffler section (it is done with a grinder). The inside of the muffler is cleaned of soot using a wire or cable. The section in the section is closed by welding.
Second method: chemical
It involves pouring water with some kind of cleaner into the muffler. For example, caustic soda is suitable for this purpose. This cleaning has the advantage that the appearance of the muffler will not be affected in any way.
Third method: heat treatment
The muffler is heated either on the scooter with a blowtorch, or dismantled in an oven or on a grill. It will be necessary to repaint the muffler only after it has cooled.
Muffler conversion
As a rule, many craftsmen not only assemble a muffler, but remake a standard one. This makes it possible to spend less time and get a more acceptable option.
Tools and materials
Before you start tuning, you need to prepare the necessary tools. In this case, the following components will be needed:
- Welding machine, preferably with different modes work;
- Pipe of appropriate size and diameter;
- Bulgarian;
- Several metal brushes for washing dishes.
Let's start tuning
First we dismantle the muffler. Then we take a grinder and cut out a piece of metal on top of the muffler. With this cut it will be much easier to work with the muffler. Almost completely cut out top part. After that you need to clear everything inner space muffler, dismantling the elements located in the section.
It's time to work with the piece of pipe that we have prepared. Using a powerful drill or welding, we make many holes in the pipe. We place the pipe in the section of the standard muffler. We select in advance a pipe of such diameter that it fits inside the standard one. It is desirable that the pipe be without any obvious flaws and perfectly straight.
The space in the cut that remains between the two pipes must be filled with metal pipe cleaners or similar materials. We weld the top of the pipe as it was. We reinstall all structural elements that were dismantled during the process.
As a result of the tuning, we will get a forward flow muffler that provides the desired result. The massive and rich roar of the engine, as well as the increase in power of the moped, will be evidence that everything was successful.
Making a direct-flow muffler from scratch
You can make such a muffler from scratch. It will be completely new option made from several components. The difficulty of this operation, called tuning from scratch, lies in finding the diagram of the exhaust system of a particular moped.
Tools and materials
In this case, again, you need to prepare the necessary tools and materials.
- Purchase in a store or find two pipes with a diameter of 33 mm;
- Buy plexiglass;
- Bolts M8 and M3;
- Prepare glue and nails;
- Welding machine;
- Needles;
- Hacksaw for metal.
Let's start assembling
First of all, you need to cut 18 cm from one of the pipes. It is recommended to carefully process the place in the cut with a needle file. From the second pipe we cut a circle with a diameter of 1.5 cm. We process it using the method described above. Glue the cut out circle in the section of the first pipe. We cut off another piece of pipe, 18 cm long. We make many holes in it. This can also be done with a sharp nail.
We connect all the parts using a welding machine. We fill the cavity formed at the junction of two pieces of pipe with mineral wool. We wrap the finished product with a special fire-resistant material. The homemade muffler is ready. To install it, you will need to attach the element to the scooter body mount.
Making a muffler mounting element
From plexiglass, which is indispensable in this matter due to its strength and easy paintability, we cut out special type rings, the edges of which can be bent outward by 180 degrees. We attach the resulting circles with serifs to the moped using the required bolts. We polish the muffler using sandpaper. To be sure, the joints between the homemade product and the moped body will need to be lubricated.
If homemade production causes certain difficulties, you can find a lot of models of mufflers already in finished form. They are usually inexpensive. On the other hand, only homemade version is able to give the ideally expected option.