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Needs Training Wheels
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 Post subject: Re: BR muffler dissection...
PostPosted: Thu Sep 16, 2010 2:33 pm 
This may be an idiotic question but, if I were gonna perform this mod would I have to take the muffler off the BR? I am guessing I would have to to make sure I can hold the muffler vertically to get out any shaving from the drilling.

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Last edited by JDI_BR on Mon Sep 20, 2010 9:10 am, edited 1 time in total.

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Iron Butt
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 Post subject: Re: BR muffler dissection...
PostPosted: Thu Sep 16, 2010 3:58 pm 
That would probably be wisest.......
but I didn't do it that way! I drilled mine out while it was mounted.

It blew out a nice cloud of metal filings when I fired it up.

Based on others experience with this mod, I would reccommend using the 1/2" conical bit (but I also didn't do this!) :oops:

I used a 3/4" bit and took about 10 minutes to ream my way through the internal welds and connectors (slowly) and I had no trouble removing the 3/4" bit when done. I used 2 locking extension bits with a set screw and retightened everything frequently.

Several others have said they had major problems with the 3/4" conical bit getting hung up halfway through the pipe and that either they switched to a 1/2" bit at some point or they wish they had later.

For that reason alone, I will reccommend using the 1/2" bit...it will do what you want done.

But..... BioHazard's stock muffler has a full 3/4" opening from rear to front. :wasted:

For simplicity and ease of extraction, stick with the 1/2" bit.

Be sure to mark the extension for where to stop drilling or you can drill a hole right through the front of your muffler if you get carried away. :banger:

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Needs Training Wheels
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 Post subject: Re: BR muffler dissection...
PostPosted: Fri Sep 17, 2010 7:45 am 
Thanks BRed. I will definately just go with the 1/2". I don't wanna do too much but the only frustrating thing on my BR is when starting it I have to rev the throttle for a couple minutes otherwise it putters out. I think this mod will help greatly with that and I would like a little more noise out of the muffler.

Any tips for making sure I drill through the center of the baffle or is that not a huge deal? I will measure it out indeed, I am worried about that the most. But if I mess up that's what duct tape is for right? :wink: lol.

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 Post subject: Re: BR muffler dissection...
PostPosted: Fri Oct 05, 2012 8:40 pm 
I'm bringing this thread back from the dead, because I'm thinking of making the mod. IF this were an electrical thing, no problem, I would have done it long ago, but mechanical things are not my best thing.

I think I understand where the hold should be, but it looks like I have to look closely at my BR to figure it out. The drawing helped a lot.


Bob

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Iron Butt
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 Post subject: Re: BR muffler dissection...
PostPosted: Sat Oct 06, 2012 1:16 am 
You want to go straight up the exhaust extension on the rear of the muffler, Bob.

That pipe runs completely through the muffler to the front and has a baffle capping it on the front end. You just want to drill through that baffle. The next thing you hit will be the front of the muffler. Stop there.

This mod allows the engine breathe better at top end....at higher speeds you can accelerate faster and it will add about 5mph to your top speed, if you've rejetted and run a high flow filter, like the K&N. It isn't really much louder, but it gives the exhaust a deeper sound...more rumble at idle and you don't need to disconnect the PAIR valve since you're still running a catalytic converter.

It also eliminates that..."fishy?"... smell from ethanol you sometimes get when you shut the engine off after a long ride. I'm not sure fishy is the right term but it doesn't smell like petroleum products. It's a characteristic of catalytic converters.

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Iron Butt
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 Post subject: Re: BR muffler dissection...
PostPosted: Sat Oct 06, 2012 1:13 pm 
bubblepuppy wrote:
Good info on this thread.

Don't know bout the BR, but on the Reflex, I can state definitively that the ignition module DOES NOT have a rev limiter feature. By my personal experience, I've seen 9k RPMs after Dr. Pulleys and car tire mods. The scoot had FANTASTIC git-up-n-go, but at 9k, the bike WILL sputter terribly, as if fuel or spark cannot keep up with actual RPM's.


I somehow have missed this post for some time but just noticed it.......

The Reflex DOES indeed have a rev limiter. What you described is an almost perfect example of a rev limiter in action!
when the bike starts to "sputter terribly, as if fuel or spark cannot keep up with actual RPMs", that IS the REV Limiter kicking in! :wasted:

The rev limiter on Hondas doesn't just cut off the spark at the limit.... it cuts off every other spark!
Fire one, skip one, fire one, skip one, etc.
The result is the bike starts to "sputter terribly" and misfire when you reach the rev limit, but it does not die completely....
(which would get you killed on the Interstate!)

On the BR, as you pass 8500rpm, your tach will show that it suddenly starts firing at 4250rpm (exactly half of the REV limit).
Here is a Veypor graph of BioHazard hitting the rev limiter on several runs from 19g sliders that were installed backwards! :oops:

Image

You can hit the limiter with a J.Costa variator, too.....if you remove 4 of the pins.
On the graph above, the green line is a stock Costa variator with all pins and the grey line is a Costa with 4 pins removed.


The Reflex ECU is REV limited to 9000rpm, so it drops back to 4500rpm on the tach when it hits the REV limit.
As soon as you drop under 9000rpm, it will start firing on every spark cycle again.

Remember your electronic tach is only counting actual spark cycles, not the actual RPM of the engine.
Only a mechanical tach could do that.

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Space Docker
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 Post subject: Re: BR muffler dissection...
PostPosted: Sat Oct 06, 2012 5:21 pm 
BRed wrote:
You want to go straight up the exhaust extension on the rear of the muffler, Bob.

That pipe runs completely through the muffler to the front and has a baffle capping it on the front end. You just want to drill through that baffle. The next thing you hit will be the front of the muffler. Stop there.

This mod allows the engine breathe better at top end....at higher speeds you can accelerate faster and it will add about 5mph to your top speed, if you've rejetted and run a high flow filter, like the K&N. It isn't really much louder, but it gives the exhaust a deeper sound...more rumble at idle and you don't need to disconnect the PAIR valve since you're still running a catalytic converter.

It also eliminates that..."fishy?"... smell from ethanol you sometimes get when you shut the engine off after a long ride. I'm not sure fishy is the right term but it doesn't smell like petroleum products. It's a characteristic of catalytic converters.


Image

I think I understand, the MOD is to take a drill through the pipe "A" to the baffle. Do NOT drill at "B" !!!!

Correct????


Bob Diaz

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Iron Butt
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 Post subject: Re: BR muffler dissection...
PostPosted: Sat Oct 06, 2012 5:54 pm 
Correct!!

A few of the first early muffler modders DID drill into the rear chamber, but that was before anyone had opened the muffler up to see what's inside.
Drilling into the rear chamber is a very BAD idea and totally disables the catalytic converter, based on what we know now.
It's like running a straight pipe.

Exhaust gases pass through the Honda muffler 3 times (front to rear, then back to the front and then out the rear), effectively making the muffler act as if it were 5 feet long.

You don't want to short circuit the flow of gases, just unrestrict that flow a bit.

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Space Docker
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 Post subject: Re: BR muffler dissection...
PostPosted: Sat Oct 06, 2012 7:34 pm 
TR does not have a LIKE Button for your posts, but if it did, I'd click it now.


Thanks, Now I can proceed without too much fear about doing it wrong.



Bob

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 Post subject: Re: BR muffler dissection...
PostPosted: Sun Oct 07, 2012 11:38 am 
Do any of us ever NOT like a post from BRed? We should just call him 'the professor'!!!


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 Post subject: Re: BR muffler dissection...
PostPosted: Fri Oct 12, 2012 1:51 pm 
just be really fawking careful if you try to drill out to the 3/4" max i.d. of the pipe

As you go in through the beginning and end of the "Resonator?" you will open up the nasty welds at each end of it

upon pulling my stepped bit out after drilling 3/4" the bit caught on the edge of what is labeled as the "resonator?" in the picture and it peeled in a piece of metal is the only way i can describe it. seemingly loosening something to rattle a bit in there. I almost lost my drill bit and found myself in a world of shit.

If i were to give someone advice it would be to limit yourself to a 5/8" drill bit and save yourself the potential frustration

as time has passed i suppose rust has set in and i can no longer discern the rattle sound and it still runs like a scalded ass'd ape :-)

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n00bie

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 Post subject: Re: BR muffler dissection...
PostPosted: Tue Mar 10, 2015 10:05 am 
Reviving this awesome thread... doing this mod this next weekend... going 5/8" like Moto Chimp suggested... :D

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