Muffler, Baffles XJ550h -81 stock

Afternoon and Happy Holidays all.

I took the stock mufflers off today as I noticed an exhaust leak the other day when I was running it. Once I got them off, I noticed some jingly bits inside.

I assume the only way to open up the stock muffler is to cut and reweld them?

 

see if the bits will shake out or vacuum out. if it is rust flakes when you start running the bike the flakes will break up and blow out.

cutting and welding may just be a bigger problem when you try to weld them

 

I shook the hell outta them and managed to get them out. Looks like clumps of carbon. Also noticed PO drilled the tail pipe. Musta wanted a bit more bark I guess. Not sure if I should plug them up or leave them.

This is turning into a nice little project. Nice though, sitting at a desk all day and coming home to tinker at this over the winter. I may enjoy fixing it up more than riding it lol.

Haven’t touched the engine yet, for valves clearances or anything or synced the carbs. Put her back to stock with the air box and got the filter the other day. She does run better just with the stock air box and filter. Front brake was seized, took that apart today. Need new brake lines,pads, tires (to be on the safe side). The more I go the more I find. Oh well it’s a long winter

 

some manufacturers drill the exhaust components to let condensation fluids out, to prevent rusting
stu