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Muffler repack required! How?

Joined May 2011
700 Posts | 3+
Wisconsin, U.S.
Hey eveyerbody,
My 600 has always been loud but i never paid much mind, today i bumped the muffler and heard a rattle like a loose baffle, i stuck my finger in end of pipe and can feel the turbine thing in end of cap flopping aroung and banging on inside of endcap, no packing left in cap at all, I understand that to repack one should remove rivets or screws from end cap repack and reinstall cap, pack main body and your done. However, the previous owner had tig welded the end cap to the body of the muffler because he was tired of loose screws and rivets :roll:

my question, if i dissassemble the muffler starting from the engine side can i still get the turbine out and pack the cap from the inside without removing the endcap from muffler? If not, is this something that could damage anything else or decrease performance in any way?

thanks in advance for ideas or responses, here is a picture of the muffler style so you can better tell what i mean
 

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If nobody knows what the inside of this muffler style looks like, or knows if i can remove the end cap baffle and repack tip without removing the endcap from the main body (remove endcap tip inerds from engine side of muffler can assembly) i will have to assume the worse and just try it, hopefully there is enough overlap between the end cap and main body that tip can be riveted again to main body after i cut out the weld and refit it...in case this happens again...
now that i found this noise it is surely driving me crazy and even though i never noticed it before at all i hear it all the time lest than 40 mph now requardless o terrain

thanks guys!
 
i had a similar problem with my 98 fe400. it seems the front of the s/a tube had rotted off. easy enough to fix on mine since the muffler was held together by rivets. best you could do is try to grind the welds so that you can slip it off. then instead of rewelding, use rivets.
 

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