Muffler Replacement
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  1. #1
    Member mra32's Avatar
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    Hey all,



    I just got a TW200. I think its an 87 and it looks pretty good for being 25. It was painted black with white bodywork and otherwise looks like its in pretty good shape. One thing that caught my eye was the muffler had a little hole on the lower seam. I took the muffler off to repair it and naturally the project turned out to be much larger than I expected it to be.



    I went to weld the hole up and it turns out that the whole area around where the little hole was has some corrosion inside and I blew through the material. I should have figured. Anyway I repaired the hole, and noticed some rattling in the muffler. I went to take the end cap off and the decades of rust held it on there. I had to drill out the screw holding the end cap on. Once i did that, the external painted portion of the end cap was free, but the inside cap was held in place. It wouldnt budge so i cut a slit in it and it was free. The spark arrestor tube was broken off from the end cap. UGH. I welded that back on and was able to fit it all back together.



    The muffler is now mostly repaired but its obviously on the way out. I am curious if there is another stockish option for a muffler.



    I did see the DG O-Series muffler for $160 shipped and I'm decently comfortable with that option, but I'm hesitant for fear of excessive noise and a need to rejet. Are there any cheapish options that will operate similarly to stock as far as sound and performance?



    Thanks

    -Mike

  2. #2
    Senior Member rm_hm's Avatar
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    My fmf without a quiet core was about as loud as my coworkers harley with drag pipes when I got on the throttle.



    The quiet core insert helped a little but it was still much louder then stock. On my 09 (with newer style carb) it went lean and started popping loud on every deceleration.



    I had the opposite results of mrbracket. My fmf lost 4-6mph on the top end. After a year of screwing with the carb without any positive effects I sold the fmf.



    My usual rides are 0 to 3000'



    Remember the 03 and up TW's have a slightly different exhaust mount than the 87-02 TW's. It's off by about 3/4 inch.











    Dustyg posted awhile back



    "Most of the exhaust mods are the TW specific FMF powercore 4 and the TW specific DG round or oval series for the TW. The FMF Turbine 2 is not TW specific, but some have used it. To date, I do not believe anyone sells a complete aftermarket exhuast for the TW. It also depends on the year of your TW. See the info below for fitment.

    The 2007 XT225 is the last year with a stainless header. The OEM part number is the same for the TTR and XT225. It will bolt up to the TW but is a little longer at the section where it attaches to the muffler. It can be purchased new at boats.net or stadium yamaha.



    So, to recap:

    1. OEM header and TW specific FMF muffler=bolt on. (2003 and beyond)

    2. OEM header and TW specific DG muffler=bolt on. (2003 and beyond)

    3. TTR 225 stainless header and FMF muffler=bolt on (2003 and beyond)

    4. TTR 225 stainless header and DG muffler= cut the header (or add spacers to front and rear) and then bolt on. (2003 and beyond)

    5. 2002 and prior bikes: The 2002 and prior bikes have a slightly shorter mounting tab on the frame and a slightly shorter distance between the two mounting points on the muffler. A short spacer is needed to link a 2002 or older OEM header to a FMF or DG muffler made for the TW "all years".



    OEM muffler part numbers:

    2JX-14711-00-00 1987-2002

    2JX-14711-10-00 2003-2012

    1


  3. #3
    Senior Member mrbracket's Avatar
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    Hi Mike,



    I've been doing a lot of testing lately with my TW on jetting and exhaust. You can see my testing on my build thread, there's a link in my signature. I'm not claiming to be an expert, I'm just a guy that's been messin around with mine for a while now.... From what I've found, you should change your jetting even with the stock muffler. It appears the factory installs a lean pilot jet, rich main jet, and buries the needle in the carb. You will find that many people on here raise the needle on their carbs and it really improves the performance.



    I assumed that I'd need to swap to a larger main jet when I added the DG muffler to my TW, but I was wrong. I actually had to go down a size to get the best performance. I raised my needle 0.060" and went with a larger pilot jet. I'm very close to having mine dialed in, it has been a lot of testing to get there.



    I now really like my DG muffler. I did not like it at first, it was too loud and gain any performance. Now that I have the jetting sorted out and added a quiet insert into it, I actually gained 4mph on my top speed and it is much more peppy.



    Again, these are just my opinions.



    You've got a friend in the Bracket Business! Hidden Content

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  5. #4
    Member mra32's Avatar
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    Hmmmm, what is your elevation, mrbracket? This will probably be ridden below 300 feet most of the time, being near Philadelphia. I am used to sportbikes with 4 individual carbs hidden behind acres of plastic so I get really hesitant to do carb work, but its probably not too bad with the single accessible TW carb.



    Does the Quiet insert require any carb changes or result dip in performance? The DG is looking attractive, but I guess its $185 with the insert, plus maybe a smaller jet?



    I'm also willing to make something work, or make adapter brackets, like a universal slip on, but I'm not sure whats game, as I'm used to sportbikes.

  6. #5
    Senior Member mrbracket's Avatar
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    I am at about 500ft elevation here where I live. The quiet insert didn't rob any performance at all. I think the wide open DG is "too wide open" for the TW, so the quiet insert really doesn't limit the flow.



    The cheapest solution would be to find a stock one that someone has removed to put on an aftermarket muffler... I'd sell you my stock one, but the shipping might be a deal breaker..... Maybe you have someone in your area that has one??



    You've got a friend in the Bracket Business! Hidden Content

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  7. #6
    Senior Member Stromper's Avatar
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    EMGO $20

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