Off Highway Vehicle Forum - ATVs | Dirt Bikes | Snowmobiles | Watercrafts - View Single Post - Pro Moto Billet spark arrestor/endcap mod

**aarons419** · 12-28-2012, 09:40 PM

Hey everyone, I just wanted to share a simple and relatively quick/cheap way to get a spark arrestor onto your dirt bike if you don't have one.

Pro Moto Billet Endos are billet endcap replacements for factory mufflers and come with a USFS spark arrestor screen. I had looked at getting a full muffler but for my bike and budget it didn't make sense because first, I wouldn't gain much of any power with an aftermarket can (what all the shootouts way back when said about the YZ426) and I didn't feel like spending $250+ to simply get USFS legal.

So I paid $134 shipped for this endcap. When I got it I was impressed with the quality. It's a very solid piece and the fit and finish were perfect for the three pieces that came in the package. Basically you get a billet end cap that inserts into the muffler and is either riveted or bolted to the can. You also get a spark screen and a color matched (to your brand, eg; Yamaha is blue, Honda is red, etc..) secondary end cap for lack of a better term, that holds your spark screen in.

So here's what I started with:

Installation was pretty straight forward since it came with really well written instructions. First up was to take a 13/64" drill bit and drill out the stock rivets. Then after they've all been drilled out you just take a center punch, or anything that'll fit in the hole really since you don't need a lot of pressure, and push what is left of the rivet into the muffler

Once that's done you simply pull the endcap out. Theoretically anyway. I ended up using a rubber mallet and tapped the "stinger" portion of the endcap to loosen it and get it to fall out. The instructions also note that you can use a heat gun to help the seal let go if needed.

Then, the new PMB end cap drops right into the muffler, once again, a rubber mallet is a nice thing to have around to tap it down since its a tight fit.

Once it's in nice and flush the next step is to use your 13/64" drill bit and drill out the end cap for the self tapping screws that are provided. It's a simple process of drilling out the hole installing the screw, and then tapping the cap with the rubber mallet to get it flush again before repeating on the next hole.

Once that's all done and the cap is secured, it's a simple matter of dropping in the spark screen and using the three allen head bolts to bolt on the other end cap.

Finished product:

I'll update this after I've taken it out and tested it on my bike, but overall I'm really happy with it.

12-28-2012, 09:40 PM	#1
aarons419 Full Access Member Join Date: Dec 2012 Location: Glendale, AZ Age: 40 Posts: 365	Pro Moto Billet spark arrestor/endcap mod Hey everyone, I just wanted to share a simple and relatively quick/cheap way to get a spark arrestor onto your dirt bike if you don't have one. Pro Moto Billet Endos are billet endcap replacements for factory mufflers and come with a USFS spark arrestor screen. I had looked at getting a full muffler but for my bike and budget it didn't make sense because first, I wouldn't gain much of any power with an aftermarket can (what all the shootouts way back when said about the YZ426) and I didn't feel like spending $250+ to simply get USFS legal. So I paid $134 shipped for this endcap. When I got it I was impressed with the quality. It's a very solid piece and the fit and finish were perfect for the three pieces that came in the package. Basically you get a billet end cap that inserts into the muffler and is either riveted or bolted to the can. You also get a spark screen and a color matched (to your brand, eg; Yamaha is blue, Honda is red, etc..) secondary end cap for lack of a better term, that holds your spark screen in. So here's what I started with: Installation was pretty straight forward since it came with really well written instructions. First up was to take a 13/64" drill bit and drill out the stock rivets. Then after they've all been drilled out you just take a center punch, or anything that'll fit in the hole really since you don't need a lot of pressure, and push what is left of the rivet into the muffler Once that's done you simply pull the endcap out. Theoretically anyway. I ended up using a rubber mallet and tapped the "stinger" portion of the endcap to loosen it and get it to fall out. The instructions also note that you can use a heat gun to help the seal let go if needed. Then, the new PMB end cap drops right into the muffler, once again, a rubber mallet is a nice thing to have around to tap it down since its a tight fit. Once it's in nice and flush the next step is to use your 13/64" drill bit and drill out the end cap for the self tapping screws that are provided. It's a simple process of drilling out the hole installing the screw, and then tapping the cap with the rubber mallet to get it flush again before repeating on the next hole. Once that's all done and the cap is secured, it's a simple matter of dropping in the spark screen and using the three allen head bolts to bolt on the other end cap. Finished product: I'll update this after I've taken it out and tested it on my bike, but overall I'm really happy with it.