How to Remove Fiberglass Packing in Baffles

Engine or carburetor modifications made to your motorcycle may require more free flowing exhaust to gain optimum benefits. The packing installed in some mufflers might cause a restriction that hinders performance. Removing the material may be the fastest and cheapest way to gain the desired results. Most motorcycle mufflers are made with provisions for this operation since packing and baffle replacements are considered maintenance procedures by some muffler manufacturers. Basic tools and rudimentary mechanical skills are all that is needed to accomplish this task.

Drill
Rivet gun
Screwdrivers
Wrenches
Rubber or plastic mallet

Instructions

- 1
  Loosen the clamp at the muffler inlet to remove the assembly from the bike to access front-loaded baffles. You can leave the muffler attached to the bike to remove baffles that load from the outlet end of the muffler.
- 2
  Drill out the rivets, or remove the set screws that retain the baffle assembly in the muffler body. Separate the baffle assembly from the muffler body by hand, if possible. Lightly strike the baffle flange with a rubber or plastic mallet to loosen stubborn or corroded attachments.
- 3
  Cut any wire or other materials that secure the packing to the baffle. Inspect the muffler body, and remove any remaining packing material. Use new rivets or the original set screws to install the baffle assembly in the muffler body. Replace the assembly onto the bike, and tighten the clamp, if removal was necessary.

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