Has anyone opened up an Ex-Box?

[DucHead]

Something is loose inside my Ex-Box. 

Rattling is audible upon start-up (no its not the clutch!), but quiets down when the exhaust heats up and the metal expands a bit.  If I stick a long screw driver in the upper outlet, the rattling stops when the screw driver makes contact with whatever it hits. 

Interestingly, the backfiring has ceased. 

There is a riveted "access panel" on top -- I see no welds, so I hope its just riveted.  Has anyone removed this?  Maybe you have a pic of what's inside?

[corey]

sounds like a chipmunk skeleton got fried onto the metal in there.

[EEL]

A good ole italian tune-up should fix that problem real quick

[Monsterlover]

drill out the rivets and report back

[DucHead]

drill out the rivets and report back

Will do, but it will be a while.

I'd like to replace the mounting bracket while I'm at it, but there's not much room to tack the bracket into place with the exhaust bolted up.

[causeofkaos]

once you have it apart many pictures are required for this thread to continue 

[DucHead]

So I drilled out the 12 rivets in the top cap of the Ex-Box, and this is what lifts out:


On the inside are three chambers all connecting to a central chamber.





Unfortunately for me, I saw nothing loose, no cracked welds (except the other side of the mount bracket), but when bounced gently, something clearly rattles on the inside.  It appears that the entire unit would need to be ripped apart and re-welded. 

I applied sealant, and riveted it back together with stainless rivets.

Time to start saving for the BoomTubes.

[He Man]

the slightest thing can cause rattling. including something like a sand grain sized piece of metal, have you tried filling it up with water and rinsing it out?

[monsta]

whats that round thing you pulled out? is that the catalyst?
does the exhaust gas flow through that or is it just hanging in space?

[DucHead]

whats that round thing you pulled out? is that the catalyst?
does the exhaust gas flow through that or is it just hanging in space?

That's a good question.  The short answer is that it is hanging in space in the central gallery.  However, its not a catalyst, more like a baffle.

the slightest thing can cause rattling. including something like a sand grain sized piece of metal, have you tried filling it up with water and rinsing it out?

I did not fill it with water, but the tone of the "rattle" when the bike is running could be replicated by gently bouncing it off the floor.

[stopintime]

Maybe one of the chamber walls is hitting/vibrating against another part in there? Could the part you touch with a screw driver, silencing the sound, be hit a little harder to change it's position?

As usual I don't know what I'm talking about - just throwing in a thought.