Muffler Re-stuff

CocoLoco

CocoLoco

FN #5
Re-stuffed my muffler. Didn't realize I was supposed to do this...or do it every 5k miles. Needless to say it was a bit overdue.

1. Tools, kit and muffler. For some reason they gave me 3x as much fiberglass stuffing as was required. Upside: now all I need to do is buy more pop rivets and o-rings and I have everything for the next two re-stuffs. :thumbup
2. The old stuffing. Found the culprit for the ragged-sounding exhaust note between 3-5.5k RPM.
3. Final product.
4. Back on the bike.

Took a little under two hours start to finish. And it was completely straight forward. Remove the muffler. Drill out the pop rivets. Pop the ends off. Remove stuffing. Replace stuffing. Reassemble. The only tricky bit was making sure to assemble it so the badge was in the right spot/direction. Fun little afternoon job.
 

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auntiebling

auntiebling

megalomaniacal troglodyte
Staff member
I'm glad you found it easy!

keep on top of it, as once the packing goes the exhaust gas can erode the carbon fiber sleeve and eventually it'll break into pieces... unless you happen tto havean aluminum sleeve with pretty CF on top.
 
CocoLoco

CocoLoco

FN #5
auntiebling said:
I'm glad you found it easy!

keep on top of it, as once the packing goes the exhaust gas can erode the carbon fiber sleeve and eventually it'll break into pieces... unless you happen tto havean aluminum sleeve with pretty CF on top.
Click to expand...

Thanks for the tip!! :thumbup

I did not know that. Just as I did not know I had to replace the fiberglass baffling every 5k miles.

The sleeve is just carbon fiber. I gave it an inspection before reassembly and didn't notice any visible signs of fatigue or discoloration. Hopefully I got it done in time and my ignorance doesn't cost me.
 
CocoLoco

CocoLoco

FN #5
afm199 said:
Good job.
Click to expand...

Thanks :thumbup

buellistic said:
As a Buell owner with a 14 inch race can......I am a expert.
After 3 factory refits. I changed to braided fiberglass rope for wood stoves.
This stuff works better than anything I have used before. Even in dirt bikes.
At least 6 times longer..this stuff is great and cheap...
https://www.oswaldsupply.com/1-4-x-...ker=7343-781&gclid=CIydmoPA6s4CFQoLaQodOMIJyg
You can get flat or round. In any length ..
Click to expand...

Thanks for the suggestion. How do you install it? Just wrap/coil it around the core?
 
auntiebling

auntiebling

megalomaniacal troglodyte
Staff member
CocoLoco said:
Do you have a slight overlap on the flat material? And Antibling says gasses can ruin my sleeve. Is your sleeve aluminum? That rope looks like it would let too much gas pass between the winds?
Click to expand...

The aluminum I'mreferring to iisn'tsomething tthatcan be added later. Some CF pipes are an aluminum pipe with a CF overlay, and they are bonded together
 
buellistic

buellistic

Well-known member
CocoLoco said:
Do you have a slight overlap on the flat material? And Antibling says gasses can ruin my sleeve. Is your sleeve aluminum? That rope looks like it would let too much gas pass between the winds?
Click to expand...

Before I used this I would blow out my Buell can out almost monthly
My dirt bike 3 months.
I like the 1/2 inch round. I coil it 3 deep. And then out a inch extra out the
End then compress the cap on.
It's the braiding that makes it stronger than the flat stuff...
 

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CocoLoco

CocoLoco

FN #5
auntiebling said:
The aluminum I'mreferring to iisn'tsomething tthatcan be added later. Some CF pipes are an aluminum pipe with a CF overlay, and they are bonded together
Click to expand...

Right. Buellistic's "can" may be straight aluminum? I imagine the exhaust gasses don't affect it the same as cf.

buellistic said:
Before I used this I would blow out my Buell can out almost monthly
My dirt bike 3 months.
I like the 1/2 inch round. I coil it 3 deep. And then out a inch extra out the
End then compress the cap on.
It's the braiding that makes it stronger than the flat stuff...
Click to expand...

In late spring this year I went on a day ride with my step-dad and his buddy. They both commented that my exhaust was sounding ragged. I really didn't think much of it. Took a long ride to Oklahoma this summer as well. I had around 10k miles on the original stuffing. Admittedly it was sounding a bit rough at low rpm and during engine break. A little research on the TBR website and found that the job needed to be done. This is my first aftermarket exhaust so I had no idea it needed tending. I don't remember seeing anything about it in the literature when I was purchasing and assembling it.

Three deep should be plenty to filter the gasses as much as the flat material. And I can probably use the remaining flat material as filler to build up the rope in an oval shape to fit the can more snugly. I have a feeling the shape of the can allows for space that led to the blowout in the old stuffing.

Thanks for all the info everyone! I will add to the thread the next time I do a restuff and I'll add more pics of the wrapped core.
 
Last edited:
Sharky

Sharky

Well-known member
Who repacks their muffler every 5K miles?

I might do the muffler on the CR under that mileage but it's a 2 smoke dirt bike.
 
CocoLoco

CocoLoco

FN #5
That's what the TBR website recommends. I have to admit their products are "for off-road use only" so they may be expecting folks to beat the tar out of them...at least moreso than I do. I think I'm going to go by exhaust note. If it starts sounding ragged again it's time to do a repack. At this point I'm thinking every ~10k miles or so. :dunno
 
westie

westie

Its Dethklok!
What I do is rap as much material around the muffler as possible then tape it tight. Put it back together and when it heats up the tape will burn off but you will have maximum packing inside.
 
northwood

northwood

Well-known member
buellistic said:
As a Buell owner with a 14 inch race can......I am a expert.
After 3 factory refits. I changed to braided fiberglass rope for wood stoves.
This stuff works better than anything I have used before. Even in dirt bikes.
At least 6 times longer..this stuff is great and cheap...
https://www.oswaldsupply.com/1-4-x-...ker=7343-781&gclid=CIydmoPA6s4CFQoLaQodOMIJyg
You can get flat or round. In any length ..
Click to expand...

Subscribed because of this. I realllllly need to do this.
 
CocoLoco

CocoLoco

FN #5
Buellistic, can you post up pics the next time you do a repack?

I may get some of the rope and do another just to try it out and see if there is difference in exhaust note. I'll post more pics of the whole process instead of the presto-chango I did for the first one.
 
Last edited:
buellistic

buellistic

Well-known member
CocoLoco said:
Buellistic, can you post up pics the next time you do a repack?

I may get some of the rope and do another just to try it out and see if there is difference in exhaust note. I'll post more pics of the whole process instead of the presto-chango I did for the first one.
Click to expand...

Got tired of packing cans.
I use Aprilia racing on my twin . All chambers .
And stock KTM 500 cans for dirt. All chambers.
Way less hassle. More time riding...no more Drilling Rivets......
Just pack it tight and go ride...
 
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