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82 XR 200r exhaust insert

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When I first picked up my XR it still had the original insert fitted into the end of the muffler, and while it ran OK, it had a definite flat spot near the bottom and didn't seem very clean through the mid range.  Pulling the insert out definitely made a big difference (really pulls well now from low down and just keeps on pulling) , making me think the previous owner had jetted it for no insert.

 

The level of noise isn't really a problem for the enduros we've been doing, but it's not a nice sound at all.

 

Has anyone played around with making a different insert that would give a result somewhere between the standard one and none at all?

 

No problem with not running spark arrestor over here either.

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Dyno test of those bikes showed a big increae in bottom end torque from removing the insert but as you discovered also a big increase in noise.

Most of the Honda inserts from that era have the same OD but several different ID are available so you may be able to find a good compromise of sound vs power.  From my notes:

 

Muffler Insert sizes:
Tail Pipe, (18311-KT0-670) has a 16.5mm ID  equals .33 sq in  used on:
86-02 XR200R,
86-95 XR250R,
87 XR600

Tail Pipe, (18311-MA0-010) has a 22mm ID  equals .59 sq in  used on:
85-87 ATC200X/350X
91-92 TRX250X
81-85 XR200R
91-96 XR250L
81-85 XR250R
83-85 XR350R
81-86 XR500R/600R
98-00 XR600R

Tail Pipe, (18311-964-003) has a 29mm ID (Dwight Rudder's fav)   equals 1.02 sq in used on:
83-85 ATC250R

Tail Pipe, (18311-MN1-750) used on:
88-00 XR600R
88-00 XR600

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Thanks Chuck,  sound like it might be a whole lot simpler than I thought it might then if they're as interchangable as that :thumbsup:

 

Not sure what size mine's got at present but it's not massive.

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Your insert should be the second one listed, measure the ID as a check.

 

I had an 82 with a rotted muffler that would no longer hold the insert so I adapted some left over 3" Supertrapp parts. Not as easy as bolting in a different insert but a possible.  I posted it in several threads, if I can find the link I'll post it. 

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I think I remember seeing the one you did with the supertrapp end in the other thread - that looked a good solution.

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