Anyone had issues with Metal Mule Exhausts?
 

Hi all,


Here's my story: I've bought a Metal Mule 2-1 exhaust in January and it took ages for it to arrive (just last Friday). Paul from Metal Mule just kept hiding behind a third party supplier which makes the heat shield. But okay that can happen.
After a lot of e-mailing and broken promises the exhaust finally arrived.
I was really happy and the exhaust looked amazing... that is until I tried fitting it.

I followed the instructions perfectly but the exhaust kept hitting the frame where the exhaust passes through the engine and the frame. I tried everything to get the required space between the exhaust and the frame but I can't manage to get it right. I started over multiple times using different ways to work for over 10 hours but still failed to get it right.

I then called a friend who has worked for a long time at a local motorbike shop as a main mechanic and he started from scratch and couldn't get it to work. The exhaust flange on the right side of the bike looks to have too much free play and it doesn't fit snug into the engine exhaust port. Even if you try to bolt it in the small left pipe doesn't align properly with the engine. The radius of the small pipe is like 2mm to big to fit and if you try to fit it you push the exhaust to the frame.
My friend said the fitting looked like the guy who made it was still drunk from the night before...:wtfk:

So my friend concluded that the exhaust would never fit the bike properly without making serious modifications to it, which I don't intend on doing as I payed a lot of money for it.

I've just send Paul another e-mail. I will let you know how this ends but I was curious if other people had the same issue?

Sorry if my English sucks by the way :)

Its a real shame when something you have waited for and looked forward to getting is not right, especially when it also costs a lot of money. All I can say is my MM exhaust was a very easy fit, probably less than an hour and I dont recall getting the pipe to fit round the frame was problem. The most difficult part was the inner exhaust manifold nut on the left hand side.

I have dealt with Metal Mule a couple of time and they have been very good with me so I am sure they will sort out your problems.

Good luck with it all.

Mate - sorry to hear of your issues with Metal Mule (MM). Your English is fine - no problems.

I recently installed the MM 2 into 1 system and I certainly didn't have a fun time doing it! I knew this to be the case before buying as there are a couple of threads on the issues:
http://www.xt660.com/showthread.php?...ght=metal+mule
http://www.xt660.com/showthread.php?...ght=metal+mule

I'm no mechanic and have access to limited tools only, so I thought my issues may have been exaggerated. However, with quite some patience, profanities and a third hand, I got there in the end. In summary:
- I don't have clearance issues
- The left side exhaust port was impossible to line up
- the link pipes could not connect due to the amount of "weld" inside the pipe that I had to remove - not a problem if you have a dremel tool - I don't.

Once the pipes got red hot, I could re-tighten all of the bolts and it has since settled into place.

On your other point regarding MM not delivering on time; I too have had that same issue. I ordered the exhaust, radiator guard, bashplate and rear rack mid November and was told at the time that everything was in stock except the rear rack, which would be delivered in one months time. I received the radiator guard and exhaust within 5 days, the rear rack in February and I have just cancelled the order for the bashplate as it was confirmed that it won't be delivered before my departure date.

I'm trying to keep the post rational, so I won't comment on the communication from MM.

Good luck with resolving your issues as the only other "bolt on" option for exhaust that gains ground clearance is the Off The Road system that is almost double to the price.

I bought and fitted the Leo Vince pipes to my XTX (I also have one on my XJR) and I found the fit and finish truly excellent and even a total non expert like me managed to fit it quickly and easily so it was surely fool proof!!! Good luck!!

I've had mine for over a year now and haven't had any issues apart from the difficult to reach bits during install. Perhaps there was a dodgy batch?

I finally managed to get the exhaust mounted.

After some emails back and forth Paul from Metal Mule suggested to cut 5mm off the end of the small downpipe because the guys at Scorpion thought it might be to long.
I tried that but it didn't fix the issue.

But when I looked closer into the pipe I found this:

http://img545.imageshack.us/img545/7100/img0083kl.jpg

I contacted Paul and he confirmed that those 2 welds shouldn't be there so he advised me to file them off which I did.

So that fixed the issue I had and now I was able to mount the exhaust with about 2mm of play so it don't hits the frame :eusa_dance:

I don't have pictures yet of the exhaust mounted completely but here's one with the small downpipe not connected.

http://img547.imageshack.us/img547/6812/img0079ze.jpg

Looking good I guess :)

nice man, glad you got it sorted

Did you get the other part of the pipe on??

Sorry to hear about your problems. I bought a used MM exhaust like yours and had the same problem. I am quite handy with the spanners but I needed to fit it about three times to get it to clear the frame and even then ONLY JUST. The pipes also wanted to rest on the engine oil filter housing.

I got it to fit by pushing it away from the engine and frame and then tightening it all up and finally the silencer. Its not really how I think you should fit an exhaust as I have always been taught to work from the front back to make sure there is no tension in the system when it gets hot etc. As my system is used and NOT mint and is on my bike for off road so cosmetics dont worry me - I bashed a bit of a flat on the link pipe to clear the frame a bit more. You cannot see this at all when fitted.

I was also disappointed to learn from two other members of this forum that their cans had been bashed by their brake calipers when the suspension had bottomed out.

Lastly, the exhaust is meant to run without any fuelling mods. Mine pops and bangs badly on the over run when the throttle has been shut off abd the bike is still moving. I have fitted the Kev fuel mod which has slightly improved it but it is still annoyingly bad. All in all it is probably the worst quality and running exhaust I have ever used. Unfortunately as someone else has mentioned the only alternatives are more than double the price and there is no point me paying that to use it off road!!

I have the same issues than you. My MM exhaust had been bashed by the brake caliper and the swingarm touches the lower part of the exhaust at full compresion of the shock.
If I fit the exhaust from the engine to the back, it touches the oil filter housing and the gap between the exhaust and the swingarm is 2cm, too much close. I had to fit it from back to the engine, it�s not the proper way but...
The bangs in the exhaust is something from the ECU, kev explains it in some post, if you have a '04-06 XT it�s harder to fix than if you have a '07-'13. I have a '04 and fixed mine with PCIII and custom fuel map with more fuel at 0% and 2% throttle opening between 1750rpm and 6500rpm. But still bangs sometimes.

Was it worth it...?
 

G'day mate

Sorry to hear about your trouble fitting the exhaust - I know how it feels - BLOODY FRUSTRATING -

I bought a Delkevic (never again) system for my GSX and the link pipe just would not fit. After a weeks messing around I sent it back for a refund and then bought a StainTune (local brand) which fitted perfectly.

So - do you think it was worth it ? Its a BLOODY BIG THING MATE... !!

Cheers

Marc

MM
 

I have a MM fitted to my 2009 XTX and I really like the look and sound. It was already fitted when I bought the bike and the last owner said it was a little tricky but nothing too bad...

Even reading all the negative posts I would still buy one based on how much I like it on my bike

It does get warm on the leg though when sat in traffic but nothng too bad (my old R1 was like this many years ago)

Yeah,

Having the exhaust fitted for a couple of weeks now I think the sound is just amazing and you can really feel the weight difference! Also it looks so good :)

I don't have a lot of problems with the heat around my leg. I even drove one day without the heat shield as the washers supplied with it burned away and I lost some of the heat shield bolts.

Ordered some new bolts on ebay and we're good to go again :)

I bought a second hand but new Metal Mule exhaust for my xtr06.. Fitted it last week and it was a pain in the asss to get fitted. Pipe touched the clutch cable, back spring and some plastic thingy near clutch cable. Tried to fit it for maybe 10 hours and always hit somewhere... so ended up taking asetylene welding torch and by heating / twisting it in 3 different places. Now it fits like a glove :) Sounds nice. Too bad here is still winter weather and i have no studded tyres so only test driven it one time..

Saves weight, gives a couple of hp, it's beautiful and sounds good when fitted, but you need a welder and a dremel to fit it...

My MM touches the swingarm at full compression of the shock, so I heated the exhaust and bent it by hand.
When I was looking closely at it to find the place where I had to make de bend I realise that it touched the inside of the frame. No problem at all, just mount it forcing a bit to the inside.

Hi guys!
This is my first post here.
Im looking in to buying an Xt660R this season and i have heard about this system.
So my question is:
Is there still trouble to mount it on the XT?
Because it�s a good price on it.
But if I�m going to tear my hair off it�s not worth it.

//GG

Compared to offtheroad.de exhaust MM can be a little bit tricky, if you manage to find a bike with this mounted it is ok but if you don,t and can afford a OTR I should do that but it will cost you a lot.

Swedish:
Om du kollar min profil vilka tr�dar jag startat s� kan du kolla hur jag gjorde m vissa modifieringar. :)

Tony



Skickat fr�n min GT-I9295 via Tapatalk 2

After riding with MM exthaust for a while now the constant popping and banging is starting to piss me off :D

Does anyone have any ideas how to reduce the amount of backfire or remove it completely? My bike is XTR -06.

Im using kev mod, snorkel removed and dna1. Also have been fiddling with the CO (7-50)but it doesnt seem to help.

Is the only option to buy PC5? if so is can i find ready made maps for this setup?

Thanks in advance :)

Hi mate,

the backfire comes from the AIS. Block it and the problem is solved. I have got MM 2 in 1 and it works fine with the blocked valve. Somewhere here you can find a thread on the topic.
That is because originally, in order to help the cat, the system is letting fresh air into the exhaust in order to burn the unburnt gases and heat up the cat faster. When you change the cans you do not have cat anymore but the "afterburner" still works. Hence the loud banging noise. By blocking the airflow into the exhaust pipe you cure the issue.
The easiest for you will be to look on the cylinder head between the exits for the downpipes there you will see a smaller shiny pipe coming out / or entering. Follow the route of that pipe and you will reach the air box. This is what you have to block. Just take out the hose which connects to the airbox and plug something into it then reconnect back to the airbox. The system will be blocked now and should not backfire. I have see people use ball bearing steel ball I have used a large bolt with round head. Just when you do it have in mind that whatever you put in the hose should be tight not letting any air.
Enjoy.

Shiiit i forget to mention in the previous post that i have blocked the AIS already.. Sorry Assenvas that i made you write such a long reply :) and thank you for that.

By blocking the ais it improved a little but still pop's and bangs a lot. I bought a second hand but new PCV but its still in the mail..

I blocked it by removing the whole system and made a cover plate from 6mm aluminium. Hand made by steelsaw and a file.

Will report back if i can make it better with pcv.. hoping to find a ready made map but seems unlikely..

Could someone recommend a map from Ask Kev section?

I was thinking of testing --> European model, Thunder 2 into 1 full open exhaust, Stock or aftermarket air filter

No problem, mate.
Have you checked the spark plug? If you have backfire it might be that your fuel mixture does not burn completely in the chamber and some goes out where it explodes. Could be that the mixture is rich. Play a bit with the Kev's mod. This might help. The bike should work smooth without PCV.
If this doesn't cure the problem, i am afraid, it might be that an exhaust valve is not closing completely letting some of the mixture out. This will be a tough job.
Keep us posted.

I would check the valve clearings also.

Valve clearings have been checked by a mechanic about 1000km ago so that should not be the issue..

My engine was taken apart because had a bad main bearing.. but it was backfiring before that also. Mechanic told me that in the engine everything looks almost new and up to specs.

I have a new iridium spark plug.. maybe tomorrow i will put that in and see if that helps.

Backfire comes almost always only when i close the throttle quickly or when engine braking. If i slow down very slowly and not close the throttle completely then it usually doesnt backfire.. Also when the bike is cold it doesnt seem to backfire due to a cold exthaust.

Anyways thanks for your help mate and i will keep you posted.

After you mentioned i might be running too rich i decided to put CO value back to stock (4). Dont know if previous owner had changed it but that what it was when i got the bike.. Anyways seems to pop and bang less, but still not as good as i would like it to be. Havent really tested properly yet but seems so.. After this weekend has gone its going to be tested properly :D

I would have changed the plug but cant find it anywhere so have to wait until it pops up or get a new one..

You can try with CO on zero and play a bit with the Kev's mod to make the mixture poorer, try few settings and follow the results

assenvas is your metalmule sticker still on the muffler? Mine burnt off after ~250km, might be due to exthaust wrap so its hotter than normal..

Will play with kev mod during weekend.. Now its set -5 degrees..

Still have the sticker but I do not know how long it will survive :D

My Metal mule fitted with out issue...
But I have dented the under side of the
muffler with the rear brake caliper under full
wheel travel...
O well I surpose it now has clearance...

I fitted my new Metalmule 2-1 system yesterday. I must really say that it was a pain in the a**. The front link pipe had a wrong angle towards the "2in1 link pipe" So it wouldn't fit without swearing and hammering ~8hours..

Well.. now it's there but it makes a strange noise, my guess is that i have a leak somewhere.. maybe where it connects to the cylinder. It might also leak where the front pipes connect together.

I'll take my bike to my local Yamaha dealer and they will tell their opinion.

Sika I've just replied your PM!

all the XT660 back fire/pop.. don't notice it so much with the standard pipes..
it's the AIS (Air Injection System) that lets air into the pipe to burn un-used fuel the
enters the pipe on a trailing/closed throttle...
blank off the AIS pipe and it will stop....

Ais is blanked off with minimal reduction of popping...

Sent from my Lumina using Tapatalk

On the early pre 2007 bikes (the ones with 00 and 01 ECUs and wasted-spark ignition) blocking the AIS will only reduce the popping, it will not stop it completely. On later bikes with single spark ignition, the backfiring can be almost completely stopped. I guess yours is a pre 2007 bike, which is why blocking the AIS has not had the desired effect?

Yes my bike is -06 with 00 Ecu.

i had power commander installed and a custom map, and it helped the popping a little but still bangs a lot. Then i found a cure, went to the shop and bought ear protection :D now it doesnt bother me so much anymore :D

Anyways i have to try and fiddle with the PCV some more and try to reduce the popping... maybe adding more fuel to 0% and 2% throttle positions. Will see what happens..