Inexpensive exhaust solution for 150cc TrailMaster 150XRS

[XD-9Guy]

I have a 150XRS that I bought used & non-running about a year ago, it's a 2013 model according to the VIN. I was very lucky in that the only thing keeping it from running was a FILTHY carburetor and bad sparkplug boot - a local ATV shop got me squared away and the little kart runs again. The two big outstanding repairs it needs now are an ignition switch and an exhaust.

The ignition looks pretty straight forward, I have found 3 wire ignitions on Amazon for less than $10 and can get one at a shop here locally for around $18. But the local shop said the exhaust is going to run $130-$140 and that is SIGNIFICANTLY more than I want to put into an exhaust. I have tried to locate a less expensive alternative online but haven't had much luck.

This is what I am trying to replace:
http://www.gokartmasters.com/trailmaster-150-xrs-150-xrx-muffler-exhaust/

Can anyone point me towards an less expensive replacement/solution?

Also of note, I have the OEM header but it's broken off. On the muffler I linked above you can see there are 4 sets of tabs that those springs are mounted on, well my pipe is busted off right before that first set of tabs, so I just have a bent piece of pipe. Is there any future in trying some hillbilly manufacturing in getting a cheap muffler and attaching it to the piece I have left?

Any thoughts and advice would be appreciated.

 

[mckutzy]

Any exhaust thatll fit the pipe can be slipped over, and clamped on. Cut a slit on the side a short distance for the pipe to bite into each other.... should be good to go on that....

 

[XD-9Guy]

mckutzy, good to know. Any idea what I do to cover the distance between where the pipe stops now and where the muffler support bracket is? If I tack on a muffler now I'll have muffler on the underside of my motor - I suspect it'll get beat up and knocked off hanging there.

 

[mckutzy]

I think well need a few pics... I'm not quite understanding..

 

[Hellion]

What's the OD (outside diameter) of your present exhaust pipe?

The possibilities are endless as to what you could rig up. Supposing that you have a place to mount a muffler that is out of the way and secure, you could bridge the gap between the two pieces with some of that flexible 'gooseneck' exhaust piping.

 

[XD-9Guy]

I will get a few pics this evening. I don't have room at my place so I store it in a family member's shop, but I'll be at his place later this evening so I'll grab that header so I can take a picture and get a shot of the opening I have to mount an exhaust in - there is a specific spot for it and it's pretty roomy considering the space there is to work with.

Hellion, that flexible exhaust pipe is new to me, but that certainly opens up some possibilities. I am off to Google to see where I can buy that stuff and how much it runs.

 

[XD-9Guy]

Never-mind guys! I found the exhaust at gopowersports.com for $99 and located a 10% off coupon. So I should be all set once it arrives.

 

[Hellion]

Cool. Show us the link to what you bought.

And every member here should know the forum 10% discount code: DIYGOKARTS

 

[XD-9Guy]

I ordered this exhaust:
http://www.gopowersports.com/aluminum-muffler-150-with-gasket-and-bracket/

and a pair of these, because my kart is missing them:
http://www.gopowersports.com/muffler-joint-nut-m6/

and the DIYGK code is the one I used!!!

 

[Hellion]

So.... $99.00 plus unspecified shipping and handling sounds like it's quietly approaching the SIGNIFICANT $130-$140 you weren't comfortable spending. I thought you were supposed to be a tightwad. What happened?

 

[Whitetrashrocker]

So.... $99.00 plus unspecified shipping and handling sounds like it's quietly approaching the SIGNIFICANT $130-$140 you weren't comfortable spending. I thought you were supposed to be a tightwad. What happened?

Lol.
What happened to DIY?

 

[Hellion]

Lol.
What happened to DIY?

I know, right? There's no shame in duct tape and baling wire.

And the added benefit--being clever and figuring out another way. A hack, if you will.

 

[XD-9Guy]

Ehhh.... Sometimes I can rationalize purchases and sometimes I can't. I guess I needed to make my peace with the expense more than anything else. LOL! I have $300 into the kart, the shop charged me $75 to get it running, I have $10 in an ignition, so at $385 I asked myself how I'd feel about having a $500 rig and I feel like that's a pretty good value.

---------- Post added at 10:19 PM ---------- Previous post was at 10:15 PM ----------

Of course like everything else in life there's always improvements to be made, there's a roll bar to replace some day and I ought to put some headrests on it so my nieces and nephews aren't smacking their heads on the gas tank.