Muffler corroded off, need advise replacing!

[SumpCommander]

Yep, as i would expect after 2 years romping in the salt marshes, the muffler finally bit the dust & split apart.. The muffler is the old design straight in straight out.. I was able to get a new muffler for the Max, but the new design the inlet for the exhaust is a 90 degree angle instead of in & out.. The muffler is affixed to flexpipe, I will have to cut the flex pipe, but if i do i was told you cannot weld to it.. Would I just be able to clamp it?.. I brought the Max to a muffler shop guy to look at, I think he was intimidated but from what he said he suggested replacing the whole exhaust manifold as well.. Im going to try to change this out myself, would clamping be suffient for the hose? anyone esle change out a muffler & have any tips? Thanks!

[Dave Smith]

That flexible exhaust pipe will clamp down with the right size clamp. If you're working on a MaxII with the side exhaust, I ended up using a short piece of straight pipe through the body and into the 90 degree muffler inlet.

[m38inmaine]

Here is what I did,

I welded a 1 1/2 elbow to a walker tractor muffler, made new brackets from some sheet metal and flared out the end of the elbow, it allows the flex pipe to slide in it, I did not clamp mine at the flex pipe and it works fine.

[SumpCommander]

Hey thanks for the responses. I just picked up some steel flex pipe, the 1" & a 1/4 pipe fits on the muffler, going to see if it fits over the exhaust manifold knuckle, or I will have to do some customization there like getting some kind of flange. Lets see how this goes!

[WaWa]

Is your Max quieter with this new muffler. I just got my Max and damn is it loud.

Here is what I did,

I welded a 1 1/2 elbow to a walker tractor muffler, made new brackets from some sheet metal and flared out the end of the elbow, it allows the flex pipe to slide in it, I did not clamp mine at the flex pipe and it works fine.

[m38inmaine]

I can't compare noise to the original as it was rusted away when I got the machine. I do know it is louder than a normal atv would be. The factory no longer offers the "outside" muffler so owners are on their own to make one up.