Muzzy Exhaust

The Muzzy pipe is a popular mod for the EX250. There are a few things to consider before you put one on, though. There is more to putting a Muzzy on your bike than pulling it out of the box and bolting it in place. Here are a couple things to consider:

• Installing a Muzzy requires you to lose the centerstand - you can't have the centerstand and the Muzzy.
• You need to rejet and fine tune the carbs.
• You need to cut the lower cowl around the pipe, as it will melt if you don't.
• While you are rejetting you might as well cut out your airbox and add some pods. You will have to pull your carbs off several times to get the jetting right. Putting filter pods on makes taking the carbs off much easier. It also increases the noise your bike makes, but if you're buying a Muzzy, you're not concerned with noise…
• If you're a high mileage rider, the stock pipes have the advantage of being maintenance-free. All other pipes require maintenance at some interval.

The melting problem

Muzzys have very tight clearances on the EX250. If you don't do something about this before you ride it, your lower fairing will melt. Some people suggest putting a couple extra washers on it; this will bring the clearance out a little. You can also use two 1 inch plastic spacers on either side of the fairing at the bolt point. You will have to get a longer bolt, though. A 6x30mm should fit. This will hold the fairing out more.

The best thing to do is trim the fairing as shown. The Muzzy pipes are a very tight fit and will press against the lower. Making a heat shield won't help much. A Dremel tool will take care of the problem in a jiffy.

One method is to let the exhaust melt the fairing back a bit to mark it, then come back later and trim it away with a dremel with a cutting wheel. You can't see the mod to the fairing without laying on the ground and looking.

Another thing you can do is wrap that small section of pipe with exhaust tape from any auto parts store. It will prevent conduction of the heat to the plastic. DEI header heat wrap can be found at hot rod shops. You may want to do some research first, as this stuff has been known to make pipes corrode quicker.

Hints, tips, & opinions

• Muzzy makes systems for two different sets of model years. The original covers model years 86-00. The newer one, with (a little) more clearance, is made for 2001->.
• Get new exhaust gaskets when you install it. The used ones will more than likely leak.
• I installed the "quiet core" and it made a big difference vs the standard one. The pipe is still loud, but the neighbors wave as I ride down the street, and I don't live in fear of cops sticking me with the loud muffler tax.

Installing the "quiet core" in the aluminum can is a pain. You have to drill out the rivets and remove a very tight fitting end cap. The core I received was a couple of mm too long, and I had to grind off a bit. Unless you are very handy with tools, I would suggest sending your can to Muzzy to install the core.

• Another take on the quiet core: It's misnamed. It should be called the "Muzzy not quite so horrendously earsplitting but still loud enough that you can't start the bike before dawn without the neighbors calling the cops Core".

Do I have to remove the centerstand to install a Muzzy exhaust?

Understandably, most people want to keep their centerstand when they put on a Muzzy system. Centerstands are very useful.

There are a few problems with this, however. First, the spring that holds the stand in place when retracted rubs the Muzzy's larger head pipe.

Second, there is no "stop" for the stand anymore when retracted (since the left canister is gone); there is nothing to keep the spring from pulling the centerstand up into the swing arm and drivechain. You could possibly fabricate a bracket to hold it in place, but it would involve some skill and is not a standard mod, so there isn't much information about it.

Lastly, the Muzzy is designed to increase performance a bit, sound good, and look good. One way it looks good is by really cleaning up the back of the bike; with the stock exhaust cans gone the swing arm is fully visible. If you leave the centerstand on, it will be quite an eyesore.

Without meaning to discourage anyone from trying, it's probably more trouble than it's worth to keep it. You can buy a nice swingarm stand for about $70-100 though, which will let you do most of the maintenance the centerstand allows. The only time you'll probably still use the centerstand is when you're doing rear suspension work; the stand can be loosely attached temporarily with two 17mm bolts, and put back in the parts bin when the work is done.

How much difference does the Muzzy exhaust system make?

One opinion

I have just finished installing my second Muzzy system. The entire system weighs just 5 1/2 lbs on my bathroom scale. The stock mufflers alone weighed 13 1/2 lbs. I didn't weigh the headpipes and centerstand but it's a few pounds more off the bike as well. The stainless steel head pipe looks great and fits perfectly. You can search the Ninja 250 board for installation tips if you need them. Less weight + more power = faster, better-handling bike.

The Muzzy is loud, but it has a deep tone; I don't think it is obnoxious. A good helmet keeps most of the noise out. Oil filter and drain plug access is fine.

Another opinion

Muzzy is a great pipe - but it's going to cost you more cash than the performance increase is worth.

Not only do you have to shell out $400 + for the pipe, you need to rejet ($), convert your air box to filter pods (optional, but most people do it)($), get rid of your center stand (buy a work stand for doing maintenance)($), cut your lower cowl (so it doesn't melt – it's not a perfect fit), and repack the core occasionally (time)($).

Sound clip

Repacking a Muzzy

FDT Muzzy 1

FDT Muzzy 2