How do I? Repack Pro Circuit R304

GraemeM
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GraemeM
Edited Date/Time 1/25/2012 8:05am
This one has me beat for now. I want to repack the muffler on my 05 YZ125. It's a Pro Circuit R304 Shorty. It looks like all you'd do is remove the three screws and the core and cap will slip out, but nope. It comes out maybe .25" and stops. There's a clicking which indicates a mechanical reason why it won't completey disassemble. I can't believe I also have to remove the rivets. Any ideas?

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Justin314
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Justin314 7/11/2009 6:05am
7/11/2009 6:05am
I have the same silencer on my 125. All you need to do is remove the allen bolts and it should disassemble. It was a little tough getting it off the first time, though. Keep trying.
GraemeM
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GraemeM 7/11/2009 3:21pm
7/11/2009 3:21pm
You know that's what I thought too, but I have had that thing in a vise and pulled and wiggled it like crazy and it won't come out. There's gotta be something solid stopping it. Damn, I'm gonna have to really *think* about this one. Or risk the wrath of the sound meter...
tunedlength
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tunedlength 7/11/2009 9:13pm
7/11/2009 9:13pm
The core is probably stuck to the bend in the outlet cap.
shoot a bit of WD into the outlet and see if that helps.
Tiki
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Tiki 7/11/2009 10:34pm
7/11/2009 10:34pm
rubber mallet helps as well.

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Rooster
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Rooster 7/12/2009 1:12am
7/12/2009 1:12am
Don't force it.

Just use a bigger hammer.
GraemeM
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GraemeM 7/12/2009 2:15am
7/12/2009 2:15am
There must be more to this than meets the eye, or I'm a dummy. I think I'd need a VERY big mallet to move this thing. The inlet cap happily rotates and comes out all of 1/4" and then just stops solid. There is a very firm metallic sound when it stops. *Something* strange here cos it's clear it's meant to just slide on out. And everyone is saying exactly that... Wonder what dumb thing I'm doing wrong? And of course, the very next video in the How To series that will get posted up ONE day on the Pro Circuit website is "How to repack a muffler" Laughing
tunedlength
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tunedlength 7/13/2009 10:46pm
7/13/2009 10:46pm
Call PC
GraemeM
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GraemeM 7/14/2009 12:02am
7/14/2009 12:02am Edited Date/Time 7/14/2009 12:03am
I got it figured. The end of the core was bent over slightly and catching on the flange inside the end cap. Enough forcing and it'd have slipped out but I wasn't game to get that serious. A few seconds prying with a screwdriver and it's all good. Just repacked it and we're good to go for the next race in a couple weeks time.

Thanks for the advice everyone, once I was convinced only the screws had to come undone I knew where to look.
tunedlength
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tunedlength 7/15/2009 9:11pm
7/15/2009 9:11pm
tunedlength wrote:
The core is probably stuck to the bend in the outlet cap.
shoot a bit of WD into the outlet and see if that helps.
so do i win anything?
MOgle80
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MOgle80 7/16/2009 7:54pm
7/16/2009 7:54pm
yes
The Rock
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The Rock 7/25/2009 11:03pm
7/25/2009 11:03pm
Use a wash plug and you will get much more life out of the new packing.....FMF makes a nice one.

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