How to Repack a Motorcycle Muffler

  • 2-3 hours
  • 15-50
What You'll Need
Replacement packing material
Full sleeved shirt
Safety goggles
Drill and bits
Plastic head hammer
Rivet gun
Masking tape
Sharp knife or razor blade

A motorcycle muffler with damaged insulation not only sounds terrible, but also affects the performance of your motorcycle. What’s more, if you continue to use your motorcycle in such as condition, you will also end up damaging your muffler.

Although many people don’t know this, a motorcycle muffler is one of the easiest things to replace in a motorcycle. Most factory-fitted motorcycle mufflers come with fiberglass packing. This packing typically begins to deteriorate after a year of use and needs to be replaced. Racing stock mufflers use more durable materials such as titanium or steel and these need to be replaced less frequently. So what should you do if your motorcycle’s exhaust note becomes louder and you experience a drop in your motorcycle’s performance? Check and replace the packing on your motorcycle muffler. Read on to find out how you should go about repacking a motorcycle muffler.

Step 1 – Don’t Roll Up Your Sleeves

Wear a full sleeved shirt and don’t roll up your sleeves. This is because the packing material contains fiberglass, and this is not something that you want to get on your bare skin. Also remember to wear gloves at all times. This not only protects you from the fiber glass, but also prevents the natural oils from your body from contaminating the metal surface of the muffler. It is also a good idea to wear safety goggles so that no fiberglass accidently gets into your eyes.

Step 2 – Remove the Muffler

Remove the muffler from your motorcycle. Clean the muffler with a soft cloth and place it on a flat surface. It goes without saying that you should ensure that the exhaust is not hot before removing the muffler from your motorcycle.

Step 3 – Remove the Muffler Core

A motorcycle muffler normally consists of two hollow tubes with a layer of packing material between them. In order to access this packing material, you will first have to remove the inner tube (the core) from the outer one. The core is normally held in place inside the body of the muffler with rivets. Use the drill to remove the rivets. Now try to remove the inner core from the muffler. You may have to tap the muffler gently with a plastic headed hammer to remove the core.

Step 4 – Replace the Packing Material

Remove the worn out packing material. Now tightly wrap the new packing material around the core. You may have to trim any extra bit with a sharp knife or a razor blade. Use masking tape to secure the packing material tightly around the core.

Step 5 – Refit the Core

Carefully slide the core back into the main muffler. If any packing material is peeking out from the end of the muffler, trim it. Carefully align the holes and use the rivet gun to rivet the core to the main muffler body. Now all you have to do is fit the motorcycle muffler back onto your motorcycle.