125-200cc WR 125 silencer repack problem

[OmerG]

Hi!

I tried to find an answer for my problem but couldn't...
I'm about to repack my silencer but i see the front end (near the engine) of it is welded.
How can I pull out the inner tube if the back end cannot be removed?
Can I just slide in the packing material without pulling out the inner tube or it wouldn't be tight in this way?

Thanks.

 

[shawbagga]

I was wondering the same thing just the other day! I like to wrap steel wool around the core before the packing but wont be able to do it with these mufflers. was thinking maybe just use the loose packing as opposed to the sheet type stuff(which is what I prefer as doesn't blow out as easy & less messy!) & just cram in as much as possible using a bit of PVC pipe or something to force it down tight. be hard to get the sheet type packing in there without it bunching up & getting it tight enough to be serviceable I reckon. crap design really. maybe just buy a FMF powercore/turbinecore or shorty?

 

[OmerG]

There is no way to pull put the core out without removing the front end?

 

[shawbagga]

don't think so

 

[Treesmacker]

Yes you can get the back cover off.
I used a seal puller.

 

[OmerG]

Thanks Treesmacker.
Maybe I don't understand you, but the front end is welded, how can it be opened without cutting it?

 

[Idacurt]

How can you weld steel to aluminum? I think you're seeing rtv sealant and mistaking it for a weld.Run a knife in the seam and see if it with cut?

Post a picture,I would be interested to see this

 

[shawbagga]

steel silencer, trust me it looks very welded. Kellys new 09 144 has the same silencer I think I saw in one of his photos. core must be welded to stinger end. can only get end cap off. sorry cant post photos. stock cr/wr muffler here in AUS(wr just longer). odd design-surely were missing something here?

 

[Treesmacker]

Thanks Treesmacker.
Maybe I don't understand you, but the front end is welded, how can it be opened without cutting it?

The pipe and outer housing are both stainless steel and they are welded together on the front end.

This is the seal puller I used to remove the "rear" end cap from our stock silencer for a 2010 CR150.
After removing the hardware insert the seal puller into the exhaust opening and "gently" work the end cap loose. Once it starts to move it will come right off.
The first time I went to repack ours I was puzzled too! Good Luck and take your time....
http://www.harborfreight.com/seal-puller-35556.html

 

[jmetteer]

It should look like this... I have never had this one apart, does the core not come out if the end cap is off?

Should be able to get to it and repack it from these allen screws...

Later,

 

[shawbagga]

yeh that's the one but the core don't come out just the end cap comes off. gotta stuff packing in there?! I didn't try force/twist/wriggle/pull the core out though??? weird design. them tyres look nasty!

 

[jmetteer]

weird design. them tyres look nasty!

Sometimes they are necessary...

Later,

 

[OmerG]

Treesmacker maybe we miss understand each other here but the problem is not removing the end cup off but pulling the core out since the front end is welded - like shawbagga mentioned.

 

[johnnyboy]

http://areapnolimits.com/products/Muffler-Packing.php

The only way to pack that is like the link shows ! Done a few myself and its a 10 minute job, the worst part is its a pig trying to clean the old carbon from the perforated core if its real bad.

 

[Treesmacker]

Treesmacker maybe we miss understand each other here but the problem is not removing the end cup off but pulling the core out since the front end is welded - like shawbagga mentioned.

Oh sorry about that. Yes the perforated tube is welded.
What I do is wrap the new packing around a used cardboard paper towel tube, slide over the perforated tube then pull the cardboard out. Then just add some more if needed.