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I tackled the installation of the 3A Racing 63-0542 muffler mod this morning and was done in about an hour. I used a reciprocating saw to cut about 1/2" in front of the welded end cap. I cut just through the "can" all the way around. I used a slide hammer to remove the OEM muffler's guts. Then, using a side grinder and a file, I smoothed out the rough edges of the cut. The OEM muffler "can" appears to be stainless steel and so I did not bother to paint the edges.

The 4A muffler is about 4.875" in diameter and the inside of the OEM muffler "can" is about 5" in diameter. I wrapped three layers of roof flashing around the 3A muffler to get a snug fit. This also gives a nice even stock-looking fit. Then I put 3 stainless steel pop rivets in the "can" under the decorative chrome exhaust shield to hold the muffler in place.

Sound is louder but has a nice mellow tone. It's not so loud as to attract unwanted attention from the popo. So, how much louder? It's about the same volume as wind noise around the OEM windshield if you're not wearing ear plugs. I had upgraded to a Clearview w/s a short while ago and was right on the ragged edge of comfort without wearing earplugs. Now, I will need earplugs; but not in place so firmly that I cannot still hear my helmet speakers.

Overall, it was a cheap, easy installation; and I'm pleased with the results. I've saved the guts of the OEM muffler as they could be re-installed with some welding. Here are pictures of the installation:

[attachment=4:3cgay9k9]IMG_0262.JPG[/attachment:3cgay9k9]

[attachment=3:3cgay9k9]IMG_0265.JPG[/attachment:3cgay9k9]

[attachment=2:3cgay9k9]IMG_0272.JPG[/attachment:3cgay9k9]

[attachment=1:3cgay9k9]IMG_0277.JPG[/attachment:3cgay9k9]

[attachment=0:3cgay9k9]IMG_0274.JPG[/attachment:3cgay9k9]
 

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Does the new muffler bottom out in the old one or is there room to play with the length?
I'm hoping to do mine tomorrow.
 

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Great job Paul. Thank you so much for the pictures and instructions. Great idea hiding the pop rivets behind the chrome shield, I never thought of that.

One question that I've been wondering about. Does the inside diameter of the 3a fit snugly over the inner part of the OEM muffler can? ( the part next to the exhaust pipes going into the housing).
Good idea with the flashing. I was thinking of using fiberglass insulation, but I guess the space between the housing and the 3A muffler wouldn't allow that.

Now I can't wait for mine to arrive, so I can do the mod also.
 

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Discussion Starter · #5 ·
The muffler bottoms out leaving the exposed part shown in the pictures. As far as the innards, it comes out as one piece with insulation surrounding the baffle tubes. They are just a couple of connected tubes inside of the insulation. Obviously, they were welded to the cap, and inseted inside the "can" before the end cap was welded on. Here's the best picture that I have:
[attachment=0:3ck3gaco]IMG_0267.JPG[/attachment:3ck3gaco]
 

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wilder days said:
Great job Paul. Thank you so much for the pictures and instructions. Great idea hiding the pop rivets behind the chrome shield, I never thought of that.

One question that I've been wondering about. Does the inside diameter of the 3a fit snugly over the inner part of the OEM muffler can? ( the part next to the exhaust pipes going into the housing).
Good idea with the flashing. I was thinking of using fiberglass insulation, but I guess the space between the housing and the 3A muffler wouldn't allow that.

Now I can't wait for mine to arrive, so I can do the mod also.
The 3A muffler has a larger outlet pipe and a smaller inlet pipe, so it (smaller pipe) will fit over your stock Honda's pipe and makes your Honda an instant 'RACECAR". :roll:

But by putting the large size pipe inside your Burgman's OEM muffler, it alows the exhaust gasses to flow unrestriced into the 3A.

Thank you Paul.

And Paul, I see a Vietnam Campaign Ribbon on your bike. Thank you for that too!
 

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Hi there Paul,

Look´s great very well done and it looks GREAT, the sound must be great tooooooooo.
I cannot wait to to the same to mine, but like a stated in another post, Im thinking of applying a bracket instead of the riverts. allthough if you revert back to the original muffler, You can spot weld the three holes of the riverts and you will not see them at all.
Im still hunting around here in Portugal for a 12,5cm diameter muffler, had no luck up to now, but will not give up.
Once again very fine job.
 

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Extreme Pornography Association?

English Proofreaders Administration?

Extreme Performance Addition? Hey, Thats it, THANKS. :cheers:

Who cares about that rip off group. And all the "Under the Table" dealing from BIG oil and manufactures. The EPA is the group that also states you can not put that Big Block 454 in your 72 Vega. :pottytrain5:
 

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Installed the new muffler today. What a difference. Here are a couple of things I learned:
1. Be certain to make your cut no less than 1/2" in front of the weld. Less than that and your original baffle assembly may still be welded to the housing. Ask me how I know!
2. I found a 5" stainless band clamp at Pep Boys that worked to not only clamp the new muffler in but also finishes off the cut end. Clamp appears it will hold the muffler in without any rivets or screws if you shim under the clamp a bit with flashing. Will post pictures when I get time.
3. Drilling the muffler is darn near impossible. Someone let me know how you got holes drilled.

Here's a comparison of the sound levels before and after. Keep in mind these measurements were taken in the garage so they're louder than they would be outside. Measurement was on the "A" scale at 6 feet. Much deeper sound.

Idle: factory 65 db new 71 db
3000 rpm factory 78 db new 89 db
full throttle acceleration to redline factory 97 db new 99 db
 

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Hi there kwaiters,

Please do post some pics of your clamp, That is exaclty what I also want to do mine, when I fine a muffler here in Portugal or Europe with the correct dimensions .
 

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Paul,

Sorry I sent you an e-mail thanking you and fogot to state the following.

As you stated that the inner dimension of the OEM muffler is 5" (12.7cm) and the A3 4.875" (12.4cm) that is a gap of 0.3cm and you wrapped three layers of roof flashing around to get a snug fit.
Don´t you think that this one will have a slightly tighter fit , it is 4.9" (12.5cm) in diameter, I will have a gap of 0.2cm to fill up, less 0.1cm the the A3, instead of three layers maybe only too layers.

http://cgi.ebay.co.uk/SILENCIEUX-ECHAPP ... 2a0e470e16

Please help me out
Thank´s
 

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Discussion Starter · #13 ·
By the way, since the 2008 has an oxygen sensor, the ECU takes care of anything that the EPA would be worried about. It will still pass an emissions check. There is also no need for a Power Commander or similar device to "fool" the ECU. There is no lean backfiring either.
 

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Can someone tell me how to post pictures to the forum? I'll post some pictures of the new muffler installation when I figure out how to do it.
 

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I'd like to know also. SO I can post pics when I do mine.

One question I have is,
On the inside of the muffler housing (OEM), is there part of the exhaust pipe that the new muffler will slide over? If so, Does the ID of the 3A fit snugly on the PIPE inside the OEM housing?
 

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paulcbrowne said:
By the way, since the 2008 has an oxygen sensor, the ECU takes care of anything that the EPA would be worried about.[/size] It will still pass an emissions check. There is also no need for a Power Commander or similar device to "fool" the ECU. There is no lean backfiring either.

How about the increase in noise level? OEM exhausts are covered by the EPA. NOISE IS A POLUTANT. Why on earth would any rational person purchase a QUIET machine and then DELIBERATELY modify it so it becomes (illegally) louder? The fact that most states do not enforce Federal Regulations is besides the point ... oh yeah, I forgot, 'If I can get away with it it's OK'.
 

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kwalters said:
Can someone tell me how to post pictures to the forum? I'll post some pictures of the new muffler installation when I figure out how to do it.
See the BurgmanUSA Tutorials at the top of the 'Newbie Questions' forum. The 'Uploading a picture within the forums' and 'Formatting an image for uploading to the forums using GIMP' will be particularly helpful.
 

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bernabeu said:
Why on earth would any rational person purchase a QUIET machine and then DELIBERATELY modify it so it becomes (illegally) louder?
For the exact same reason that many add additional lights, storage, custom seats, graphics, custom paint, communications/radios/MP3 players ,etc .... to customize their bike to what they want. Not everyone has the same priorities. And while it does produce more sound, it's nowhere near the amount the hordes of cruisers create.
 

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How about the increase in noise level? OEM exhausts are covered by the EPA. NOISE IS A POLUTANT. Why on earth would any rational person purchase a QUIET machine and then DELIBERATELY modify it so it becomes (illegally) louder? The fact that most states do not enforce Federal Regulations is besides the point ... oh yeah, I forgot, 'If I can get away with it it's OK'.
Because we can.
The cool factor
To turn heads
because we want to
Because we like the sound of a rumble when we ride
Because we're looking for something new to do to/with our scoots.


You like you r scoot quiet, others want a little "Ballsy" sound to there scoot.

Finally....because not everyone is a Rational person...LOL

RUMBLE on dudes.....
 

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bernabeu said:
<<<Snip>>>Why on earth would any rational person purchase a QUIET machine and then DELIBERATELY modify it so it becomes (illegally) louder?
WHEN they start pulling over all those POS Harleys that have loud pipes, then I guess we can worry about a increase of a few Db's this mod will add.

If I'm not riding it by your house at 2 AM, why bother asking why. Its one of Mary, Mary quite Contrary.
 
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