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Hi there all,

So I picked up a ninja 250 (2003) because it fits down the hurricane doors into my basement where I've now stored it and am getting ready to do some serious work on it (the previous owner laid it down a lot and didn't maintain it very well at all lots of rust and that sort of thing). Before I put it away I kept hearing this loud rattle from the right side exhaust when the bike's running, it sounds as if there's something inside the pipe bouncing around, especially when I lean the bike side to side, but it only happens when I'm running it, i.e. I can't shake it up and down and hear a rattle (except from a loose sleeve). Any way to test whether the muffler's just broken and I need a new one? Or should I just leave the visor up so the wind noise blocks out the rattle? Thanks!

You probably have a baffle inside the muffler that has either broken loose entirely or is still hanging on with a tackweld. I'd guess at the second one since it only happens when running, the engine exhaust pulses are making it rattle.

Have you had the muffler off the bike yet? Can you hear the rattle shaking it in your hands? You can try shaking whatever it is out hole on either end..... I doubt the stock can can be opened up without a torch, but you might be able to remove the plate on the back of the muffler by drilling out some rivits or something. Doubtful though.....

noobie mcnooberson wrote:should I just leave the visor up so the wind noise blocks out the rattle?

Haha, that's the spirit!

The muffler might be loose where it bolts to the frame. Not sure how much the EX-250 is like the EN-450 (or EX-500, which I thing bolts the same), but one of the mufflers on my 454 got loose at the frame bolt. Maybe try tightening there.

Then again, it might be the can itself or the baffle as mentioned previously.

--Dave

also if there is a chrome cover on the bike make sure the band is tight that holds it onto the bike. Otherwise, while it's idling, just touch around the muffler (before it warms up ) and see if you can push anywhere and have the noise stop.

good luck
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