[2005DMAX]

OK, here is some pictures of the inside of the stock muffler. Not what I thougt it would be. Any way, I cut both ends of the muffler open and on the inlet to the muffler I welded on a small shield, thinking it might dampen the sound a bit. As you can see from the pictures, there is very little packing matierial in this muffler, so I added some on the front side of the muffler, and both end caps.

To try and minimize exhaust fumes inside the RZR, I removed the exhaust tip from the back, and welded it on the bottom side.

I won't know what it truly sounds like until I get my spark arrestor installed. The bolt came loose and I lost it. Dealer ordered me a new one.

Once I get the other oem muffler that I just bought, and get the spark arrestor installed on this one, I will compare sound levels to see if it is any quieter, or if I just waisted a day of my time. I will keep everyone updated on the results.

This is the inlet side of the muffler.

Shield and extra packing matieral

This is the outlet side of the muffler.

Finished and installed

 

[Bigdog800efi]

You definatly did not waste time. Projects like that are huge lessons learned for you and for eveyone you inform. Let us know what the results are. I really want to hear them.

 

[2005DMAX]

Well, from behind, it does not appear to be much more quiet. From the drivers seat it sounds quieter, most likely due to the exhaust tip being turned down. The big thing is I have no more exhuast fumes in the cab.

 

[GRAZOR]

I have been waiting for someone to figure a way to tone it down a little and especially for the hunting season.

Too bad your fix didn't have much effect.

I got rid of the fumes with a $5 elbow pipe from advanced auto and a little fab work to essentially do what you did. I do notice it is quieter for me inside but not much difference when I'm out. I suspect polaris may add some sort of turn down tail pipe in the near future since so many complain about the fumes with the windshields installed.

I'm still surprised they have not addressed the manifold fire risks yet.

Gary