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1984 xl200 exhaust

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I am uncorking a vintage 1984 Honda XL200R. I have addessed the airbox, jetting and header pipe. I only have to remove the exhaust baffle to complete the project. However, it appears that the exhaust end cap is not held in by bolts/screws but is actually WELDED. Am I out of luck or do I need to cut the pipe to get at the baffle and then install an aftermarket exhaust tip. Any thoughts?? Thanks for looking, Scott

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The whole end of my exhaust ('82) fell out so I welded it back in. Maybe that's what happened to yours.

- Brad

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Thanks for the quick response. The end cap is certainly welded and I am the third owner...I MAY have have to cut the end off, remove the baffle, and then simply weld/braze the cap back on. Scott

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I don't believe the stock muffler can be disassembled without cutting. I upgraded to a Cobra slip on, they come up on ebay occasionally, I also have a supertrapp from an early xr200r that fits 83-84 XL's without too much hassle.

May I ask what you did to address the header pipe? in my opinion the XL is the best flowing (largest diameter anyway) stock headpipe I have seen on any 2 valve 200. I have done a lot to my 83 to make it faster and keep it reliable, I think higher compression, a bit better cam and then an XR carb in that order would be the best recipe if I were to do it all over again, the exhaust gave the smallest noticeable increase in performance, after everything else was done.

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I found the stock header to be relatively clear and free of the any welding slop. The bike really responded well to upping the Main jet to a 115 and the installation of an UNI filter. However, I may have to start checking eBAY for an exhaust system...Thanks for the insight on value of a higher comp piston kit..maybe a call to Powroll in the future? Thanks for looking, Scott

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