What To Do...? Muffler Rattle...

[fun2scoot]

When I removed the Exhaust on my 2015 PCX150 in order to change the tire I heard something loose inside the muffler - rattling. I assumed the baffle had broken loose, but I'm no longer sure that is the situation. With no skill at welding I am reluctant to cut it open - especially so because where the pipe enters the muffler the precise bolt spacing from the exhaust port to the three mounting bolts would be difficult to duplicate.

Broken Weld small.jpg (381.81 KiB) Viewed 1560 times

A Eureka! moment occurred when I closely inspected what my poor eyesight had originally missed; a separation of a few thousandths of an inch where the pipe joins the muffler body. If I hold the two tightly together there is no more internal movement, yet no weld exists here. I suppose I could get someone to weld the break but I wonder if it is not so simple.
Only the muffler body is moving at the break - the pipe is still solidly attached to the internals.

Has anyone opened one of these, and maybe has some pictures?
I'd appreciate opinions as to whether there might be other welds inside needing mending. Or, if there are and I only get the break welded could that lead to other, unforeseen, problems?

Thanks all!
David

[Davepcx]

You could have a local welder put a couple of tack welds on it first to see if that fixes the rattling?

[fun2scoot]

Thanks Dave. If no pictures of the interior exist then that is what must be done and, if it still rattles I will have little choice but to cut the end off and look for a broken weld there.
I may have located a local welding shop with sufficient expertise to weld such thin metal.
I'll report back with the results so that someone else with a similar problem might have a starting point.

[easyrider]

You can also try some Permatex muffler mend putty. If it works you may be good to go or you can weld it later on if it gives out.

[you you]

You can also try some Permatex muffler mend putty. If it works you may be good to go or you can weld it later on if it gives out.

That stuff never lasts and won't replace a weld. A couple of quick tacks will sort it.

[WhiteNoise]

How bad is your muffler overall? Looks crispy. I'm thinking New muffler/exhaust? Just under $400.
Bit of an Ouch!!!
But maybe worth buying if you're keeping her awhile and have the dough to part with.
I'd prefer that route meself.

[easyrider]

You can also try some Permatex muffler mend putty. If it works you may be good to go or you can weld it later on if it gives out.

That stuff never lasts and won't replace a weld. A couple of quick tacks will sort it.

The permatex is just a test to see if an external weld would cure the issue.His last paragraph indicates he is not sure if a weld would fix the internal noise if it is in fact internal.If the temp mend works then he can commit to a permanent steel weld.Its merely a diagnostic ploy on the cheap.

[Davepcx]

Thanks Dave. If no pictures of the interior exist then that is what must be done and, if it still rattles I will have little choice but to cut the end off and look for a broken weld there.
I may have located a local welding shop with sufficient expertise to weld such thin metal.
I'll report back with the results so that someone else with a similar problem might have a starting point.

It really takes no welding expertise at all to put a few tacks on then if that does fix the problem anyone with even a hobby welder could run a permanent seam weld on it...
Other than the crack the exhaust looks in pretty good condition , i personally wouldn't dream of replacing the whole exhaust for such a simple fix...

Let us know how you get on...
Dave.

Edit since new post:
It would probably cost more and be more messy trying to use permatex than the tack weld option...

[easyrider]

Would not be messy at all to seal with putty.If it solves the issue it gets cleaned off with grinder as it would be required anyway to do final weld.So there is no mess.If he has a welder all well and good but if he has to take it to a shop and the weld doesn't work it becomes two trips to the weld shop instead of just one.If he has a welder then all is good.Sounds to me like a baffle is loose on the inside and when he presses on the crack the baffle is quiet.I agree the muffler otherwise looks good.Should be easy to repair.

[springer1]

How bad is your muffler overall? Looks crispy. I'm thinking New muffler/exhaust? Just under $400.
Bit of an Ouch!!!
But maybe worth buying if you're keeping her awhile and have the dough to part with.
I'd prefer that route meself.

+1

[fun2scoot]

Here is the latest;
After some local welding shops gave un-confidence inspiring responses, I just happened to mention the problem to a friend who works in an automotive body shop and, bingo!, he said he does that kind of welding regularly, would not charge me, and that an inexperienced welder would almost certainly weaken the metal.

I got the muffler back yesterday and the weld looks beautiful - if a weld could be described so. Almost robotic. Not a singe on the metal. Installed it and headed into the sunset in quiet bliss.

Hard to believe this failure is unique to my bike. It might be a good idea for PCX150 owners to remove the plastic protector and carefully examine the underside of the muffler for a paper-thin separation as in the photo above. I hope this is unique because otherwise it may be a design flaw.

[you you]

Fantastic

[fun2scoot]

Fantastic

It is You You and thanks. And thanks to all for the suggestions and discussion. Kept me from straying from the right path.
I just hope my experience helps someone else.

[power-full]

Here is the latest;
After some local welding shops gave un-confidence inspiring responses, I just happened to mention the problem to a friend who works in an automotive body shop and, bingo!, he said he does that kind of welding regularly, would not charge me, and that an inexperienced welder would almost certainly weaken the metal.

I got the muffler back yesterday and the weld looks beautiful - if a weld could be described so. Almost robotic. Not a singe on the metal. Installed it and headed into the sunset in quiet bliss.

Hard to believe this failure is unique to my bike. It might be a good idea for PCX150 owners to remove the plastic protector and carefully examine the underside of the muffler for a paper-thin separation as in the photo above. I hope this is unique because otherwise it may be a design flaw.

good I had to weld my whole also in this zone my pcx is 2010 .. will be the speed?
lol