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Self installation instructions for
Helmets and Speakers


Determine if ear noise reduction muffs will fit in your helmet.
Helmet Speaker Installation | HJC 2012 Model CL Max ll Modular Helmet Installation | HJC 2002 Model SY Max Modular Snowmobile Helmet Installation
Arai XD4 Helmet Installation | HJC 3/4 Open Face FG-JET Snowmobile Helmet Installation | Shoei Neotec Modular Helmet Installation
Scorpion EXO-900 Furtive Transformer Helmet Installation | 2003 Bombardier Advanced Tec BVS Modular Snowmobile Helmet Installation
Motorcycle Half Helmet Installation | SnoForce Full Face Helmet Installation | Ski-Doo Modular 2 Helmet Installation | Tools Needed to Modify All Helmets

Arai XD4 Helmet Ear Noise Reduction Muff Installation

An Australian couple, riding on BMW's and traveling with their dogs through South America, Mexico, and parts of the U.S., ended up at Quiet Ride Muff/Helmets headquarters in Grand Rapids, Minnesota for two days to install ear noise reduction muffs in their Arai helmets to protect their hearing.

Stu and Janell from Australia

The picture above was taken on the last unusually warm fall day (high 82 degrees) in Grand Rapids, Mn. on Sunday, Oct. 11, 2015 after installing an ear noise reduction muff kit in each of their helmets. My wife and I, Patti and Al Halfaker are standing to the left of world travelers Stuart and Janell Clarke from Australia holding two of their three dogs that ride with them as they tour the U.S. on their BMW 650GS bikes. Stu and Janell started biking through South America 19 months ago and now have 54,000 miles on their BMW's.

You can imagine that they developed a well thought out plan of what to bring and the camping equipment they would need and the equipment needed to transport their extended dog family on their "Trip of a Lifetime."

There was only one problem: they didn't realize the effect of the excessive wind noise decibels at 60 mph over 4 to 8 hours per day they'd experience for many days over 19 months and 54,000 miles. Wearing ear plugs were not an option as they are painful to wear and eliminated the possibility of communicating with each other through their Sena intercoms. Stu and Janell clicked on our quietridemuffs.com website two months ago and discovered it would be possible to install noise reduction muffs in their helmets that would allow them to protect their hearing and at the same time allow for much better communication and enjoyment of music.

I received an email from Stu and Janell through the Adventure Rider website on Oct. 3, 2015. They were in southern Wisconsin and were planning to come through Grand Rapids, Mn. and wanted to stop at our home to install the kits. Their websitesite is thepacktrack.com, and their Facebook page is facebook.com/Thepacktrack. I highly recommend viewing their web page and following their facebook page as these two highly adventurous young people travel through the rest of the U.S.

Stu and Janell camping in my front yard

Stu and Janell arrived Friday evening, Oct. 9, and set up camp in our front yard for two evenings while we installed the ear noise redution kits in their Arai XD4 helmets. In January 2016 they plan to bike through Europe, Africa and parts of Asia as they make their way back to Australia.


The installation of ear noise reduction muffs in Arai XD4 Helmet
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Ear Muff Speaker Instructions 1
1. Remove side padding.

2. After removing the side padding, install helmet on head. Install the ear noise reduction muffs with the air bladder under the ear muff in the helmet shell with ear muffs up against the EPS white Styrofoam. The ear muffs will not go high enough in the helmet shell to fit around ears properly.

3. Take a short knife and to cut about a half inch or more of EPS Styrofoam out of the helmet shell so the muffs can go up higher and fit properly around the ears.

Step 2
This picture shows the top of the ear muff located in cut out section of EPS Styrofoam in helmet top so it will fit properly around ears.
 
Step 3

In the picture above, the ear muff is in the proper location to fit
comfortably over the ear.

Notice the metal chin strap connector has been pop riveted into a new location down and forward on each side of the helmet so the chin strap connector is not under the ear muff.

Step 4
Above is a picture of Janell Clarke just after a drilling hole in the right side of a helmet for the new location of the metal chin strap connector that will be pop riveted to the helmet.
 
Step 5
The Picture above shows the new location of the metal chin strap connector on the right side angled down 1 1/2" lower on the side of the helmet and forward about 1". The pop rivet used is a 3/16" by 5mm to secure the metal chin strap connection to the chin strap on each side of the helmet.

Step 6
A high speed power grinder with tear drop diamond tip was used to grind off the head on the original pop rivet holding the metal chin strap. It was located under the ear noise reduction muff and interfered with the installation.

Step 7
Stu Clarke is cutting side padding. He has removed excess foam padding so the remaining side pad will fit around the ear noise reduction muff. The picture shows Stu cutting away extra cloth that was covering the side foam padding before some of the foam padding had to be removed.
 
Step 8
Much of the side padding on each side has been removed to make room for ear noise reduction muff. In the picture above, the remaining side pad has been wrapped with cloth and glued to the back of the ear muff pad with Goop silicone.

Step 9
This picture shows the back side of the ear muffs with Velcro stuck to what is left of the ear muff pad. This will stick onto Velcro that was stuck on the inside of the helmet shell around the ear noise reduction muff location to hold the side pads in place in the helmet.
 
Step 10
Here Janell is installing the customized side pads back into the helmet around the ear noise reduction muffs.

Step 11
Stu and Al are contemplateing how the air bladders should be placed under the ear muffs and Velcroed to the inside of the helmet shell and how the air lines from each air bladder will connect to a plastic "T". An air line will need to run from the plastic "T" to the air pump on the left side of the helmet.
 
Step 12
The air line from one air bladder under ear muff is connected to the "T", which is connected to the air line to the air bladder under the ear muff on other the side of the helmet. The airline comes out of a hole made in the padding in the back of the helmet and goes to the air pump on the left side of the helmet. The airline was wrapped with Velcro and Velcroed to a Velcro piece stuck onto the back padding to hold the air lines in place. Note the line to the Sena HD speaker passing through the ear muff through a hole drilled in the ear muff.


Directions for Installing speakers in Quiet Ride Ear Noise Reduction Muffs
Step 13Remove electrical tape covering the seam between the ABS cream colored cup and the black ABS washer with the ear muff stuck on washer.

Drill a hole in the ABS cup for the speaker line to enter ear noise reduction muff. Drill size should be the same diameter as the speaker wire is that will go through ear muff.

Step 14
Unsnap ABS washer from ABS ear muff cup.
 
Step 15
A small channel lock pliers also works great to separate two parts

Step 16Use a knife or wire cutter to make a slot for the speaker wire to fit into snuggly.

Step 17
Unsnap ABS washer from ABS ear muff cup.
 
Step 18
A small channel lock pliers also works great to separate two parts
Use knife or wire cutter to make a slot in the back of the ABS washer that snaps onto the cream colored ABS cup so the speaker wire can fit into the slot.

Step 19
Use a knife or wire cutter to make a slot for the speaker wire to fit into snuggly.

Step 20
Speaker wire laid in the slot of the ABS ear muff cup, ready to have the black ABS washer snapped back onto each ABS ear muff cup.
 
Step 21
Speakers are Velcroed in the ear muff cup in proper location.

Step 22
Speakers are offset in the ear muffs so the flap of ear will also fit in cup
comfortably when the ear muff pad seals around the ears.

Step 23
Left side speaker location in ear noise reduction muff
 
Step 24
Right side speaker location in ear noise reduction muff

Step 25
 
Step 26
A good demonstration picture above of motocross helmet showing proper speaker location in right and left ear noise reduction muffs in helmet.

Step 27
Side pads have been Velcroed back into place around the ear noise reduction muffs. Looking good!!!
 
 

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Dangers of wearing ear plugs
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Helmet speaker installations
Arai XD4 Helmet Installation
Bombardier 2003 Tec BVS Snowmobile Helmet Installation
HJC 3/4 Open Face FG-JET Snowmobile Helmet Installation
HJC 2002 SY Max Modular Snowmobile Helmet Installation
HJC 2012 Model CL Max ll Modular Helmet Installation
Motorcycle half helmet installation
Scorpion EXO-900 Furtive Transformer Helmet Installation
Shoei Neotec Modular Helmet Installation
Ski-Doo Modular 2 Helmet Installation
SnoForce (full face) helmet installation

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