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Project: Aquire a CRF 450R exhaust can and convert for trail use by installing the ProMotoBillet Endo end cap with spark arrestor.



Tools needed: Drill, 3/16” drill bit, Hi Temp Silicone Sealant, Rivet Gun, Center Punch, 1/16" Pin Punch, Hacksaw, Allen wrench

Step One:

Use a 1/16" pin punch and a hammer to drive the stainless steel rivet pins through the rivet.



Step Two:

Using a 3/16” drill bit, drill out the existing rivets holding the stock end cap in place, make sure to remove the head of the rivet.



Step Three:

Use a pin punch or similar device and a hammer, push the rivets through the hole and through the stock end cap.



Step Four:

Pull the stock end cap out of the muffler. Remove all
pieces of the old rivets from the packing material inside of the muffler canister.



Step Five:

Cut off the portion of the inner core that is sticking out of the muffler so that it is flush with the outer canister of the muffler. This is easily accomplished with a hacksaw. Be careful not to cut into the aluminum canister. The inner core must be flush with the aluminum canister or the spark arrestor screen could be damaged.



Step Six:

Smear a small amount of silicone sealant to the stepped portion of the new end cap receiver and around the receiver of the inner core. I used this sealant ( Hi Temp Silicone ).



Step Seven:

Install the new end cap receiver, make sure that the receiver is pushed up tight to the muffler.



Step Eight:

Install one rivet at a time by drilling a 3/16” hole at each rivet hole location. Each time you drill a hole and install a rivet make sure that the end cap is pushed up tight to the muffler.



Install rivet.



Step Nine:

Clean up excess silicone sealant with Lacquer Thinner or Carb cleaner and paper towel.



Step Ten:

Insert the spark arrestor screen and check for clearance with the inner core.



Step Eleven:

Install the cone nozzle with three M6 bolts using an Allen wrench.



Finished!!!!



Optional Step Twelve:

Remove lower M6 Bolt and install Quiet core.

this is the setup i plan on doing as soon as i find an 05R can for cheap. Except i think i would skip step 1 and just drill them out to begin with also skip step 12 but keep the insert on hand just in case.

paul turner wrote:I partake of the buttons too, wow, i'm hungry !

I considered buttons too, for ease of serviceability.

Even went as far as buying them.

After seeing that the thickness of the aluminum end cap was less that 1/16", and if I tapped it with even a fine thread, I was going to only have about 2 threads in aluminum to hold the screw. No opportunity for a nut on the backside.

The rivets, for me, was the only real solution...

Been riding single track in the Bridger Forest in Montana. Note the silver (camo) end cap!
Almost got taken out by a very large elk while movin' along in fourth gear. Then came around another corner and scared up a black bear sunning himself in the middle of the road. Baja is exciting but this is frightning!

Caballo Rojo wrote:Been riding single track in the Bridger Forest in Montana. Note the silver (camo) end cap!
Almost got taken out by a very large elk while movin' along in fourth gear. Then came around another corner and scared up a black bear sunning himself in the middle of the road. Baja is exciting but this is frightning!

Caballo Rojo,
I am originally from Bozeman, but being that it is Montana, spent 100% of my time in the Bridgers on a snowmobile, not a bike. Anyway, that last pic looks familiar, fairy lake?

Finally set my new r can up today. Man it really seems crisper, and definitely a helalot lighter.



Was trying to find the thread about adding pictures but couldn't find it.

jtsurfs wrote:Finally set my new r can up today. Man it really seems crisper, and definitely a helalot lighter.



Was trying to find the thread about adding pictures but couldn't find it.

Looks good. I've had mine for about a year. The only downside is it's starting to look pink instead of red. Apparently this happens to all of them.

I called Pro Moto before buying mine and asked it they could make me one that was not anodized. They said yes, but it would be a month before the next run. I was too impatient for that.

Sound-wise, I love mine. Has a higher-pitched raspier sound than most aftermarket stuff, like the Two Brothers M7 for example.

Used button heads on mine instead of rivets....

I liked the look of yours just hadn't had the time to pick up the button heads.

I figure if it starts to turn pink I will get the tip powder coated black.

So for my 05X I will need a 05r can?
Or what years will fit?

Sir O.T.B. wrote:So for my 05X I will need a 05r can?
Or what years will fit?

Yep, only the 05R can will work.

Sir O.T.B. wrote:So for my 05X I will need a 05r can?
Or what years will fit?

Welcome to the site!!!

ONLY the 05 R can will fit without modification.

Oh yeah, without modification.

After some searching, it looks like I may need the muffler gasket for the 05' which is part number 18392-MEB-670.

ChrisLuce wrote:After some searching, it looks like I may need the muffler gasket for the 05' which is part number 18392-MEB-670.

is the gasket that fiberglass looking piece that i took out between the muffler and the head pipe? should i put that back in? maybe thats why its backfiring so much when i first start it cold.

rob_wiggins wrote:

ChrisLuce wrote:After some searching, it looks like I may need the muffler gasket for the 05' which is part number 18392-MEB-670.

is the gasket that fiberglass looking piece that i took out between the muffler and the head pipe? should i put that back in? maybe thats why its backfiring so much when i first start it cold.

Rob,

I am not sure what this one looks like BUT I just replaced the stock mufflers on my sons new 250R and I believe they are a soft silver looking gasket. I am sure the local shop will not have them in stock so I am sure it will take a week or so to order. Yes, I suggest putting it back in.

Chris