When it’s time to repack the muffler on your ATV or motorcycle, who do you turn to? Your mechanic? Your buddy? How about yourself? Anybody can learn to repack a silencer by following the steps below. And once you get it repacked, you’ll be back on the road with a machine that sounds great and has plenty of power.

Rear View Picture of an ATV and Silencer

How to Repack an ATV or Motorcycle Muffler

All you need in order to repack your exhaust is good tools, new packing and the right know-how. You can take a look at the video shown here to see how it’s done. Or if you’d prefer written instructions, you can read those below.

These instructions are based on the Lexx MXe silencer. However, the process is similar on most 4-stroke and 2-stroke exhausts.

What You Need to Begin

Picture of Lexx MXe Premium Silencer Packing

Of course, the primary thing that you’ll need to get started is new silencer packing material. The material demonstrated in this tutorial is Lexx MXe premium. Take a look at quad or motorcycle exhaust accessories to see what is available. At Rocky Mountain ATV/MC, we carry several great options you can use.

Parts Needed to Begin
Picture of a Tusk Hex Key Wrench Set Picture of Permatex Ultra Copper Maximum Temperature RTV Silicone Picture of a Rubber Mallet
Hex Key / Allen Wrench Set High Temperature Silicone Rubber Mallet
Picture of Masking Tape Picture of Latex Gloves Picture of a Bike Master Scraper Wire Brush Set
Masking Tape Gloves Wire Brush
Picture of a PVC Pipe Picture of a Yellow Electric Drill
PVC Pipe or Wooden Dowel (Possibly) Drill and Rivets (Possibly)

Open the silencer.

  1. Remove the cover off the back of the silencer.
  2. Picture of Removing the End Cap

  3. Remove the two end pipes.
  4. Picture of Removing the Quiet Core Insert

  5. Remove the quiet core.
  6. Picture of Removing the Inner Quiet Core

Remove the end cap.

  1. Unscrew the six Allen heads placed around the diameter of the silencer.
  2. Picture of Unscrewing the Allen Heads

  3. Some silencers may have the screws on the front of the silencer instead of the back.
  4. Picture of FMF Silencer with Screws on the Front

  5. Some exhausts may not even have screws at all, using rivets instead.
  6. Picture of Yoshimura Silencer with Rivets Instead of Screws

  7. If your silencer has rivets instead of screws, you will need to drill them out in order to repack your muffler. When you are finished, you’ll need to rerivet them as well.
  8. Picture of Drilling the Rivets Out of a Silencer

  9. Once the screws are removed, most silencers will have a lip on the end cap to keep it in place.
  10. Picture of the Lip on Silencer End Cap

  11. Place the silencer over a PVC pipe or wooden dowel aligned vertically. You can put it in a vice to get it positioned correctly.
  12. Picture of Placing Silencer on PVC Pipe

  13. Using the PVC pipe or wooden dowel, gently tap the end cap from the inside. It will pop out, and you can remove it.
  14. Picture of an End Cap Popped Out

Remove the core.

  1. Pull out the core.
  2. Picture of Pulling Out the Core

  3. Remove whatever is left of the existing packing material. Please note that the packing material in the image below is still in relatively good shape. You may have much less, or it may be discolored. This is no cause for alarm.
  4. Picture of Removing the Existing Packing Material

  5. Clean the core with a wire brush. This is also a great time to inspect it for any damage.
  6. Picture of Cleaning the Core with a Wire Brush

Wrap the new packing material around the core.

  1. Make sure that your new packing material is the same width as the length of your core. If it isn’t, you must cut it.
  2. Lay the packing material out and position the core at the end.
  3. Picture of Laying Out the Packing Material

  4. Roll the core in the packing material. Roll it as tightly as you can. This will make later installation easier.
  5. Picture of Rolling the Core in the Packing Material

  6. Wrap masking tape around the packing material. This is used to keep it as tight around the core as possible.
  7. Picture of Wrapping Masking Tape Around the Packing Material

  8. Take a look at the ends. Make sure that they aren’t obstructed by any excess packing material.
  9. Picture of Observing the Ends of the Packing

Install the core with the new packing material into the silencer.

  1. Push the core and packing material back into the silencer as a single unit.
  2. Picture of Installing the New Packing Material

  3. Slowly feed the packing material into the silencer as you simultaneously push down on the core. If you just push the core, it may slip out of the packing material, and you will need to roll it again.
  4. Picture of Feeding the Packing Material While Pushing the Core

  5. Make sure that the core engages the front cap. You may need to place your thumb inside and guide it as you finish pushing the core into the exhaust.
  6. Picture of Looking Down into the Front Cap

Reinstall the end cap.

  1. Clean the end cap with a wire brush.
  2. Picture of Cleaning the End Cap with a Wire Brush

  3. Apply high temperature silicone to the edges of the end cap. This will help seal it.
  4. Picture of Applying High Temperature Silicone to the End Cap

  5. Place the end cap back onto the silencer. Make sure that it fits correctly with the core and that no packing material is in the way.
  6. Picture of Replacing the End Cap

  7. Use a rubber mallet to get the end cap snugly in place and flush with the silencer.
  8. Picture of Using a Rubber Mallet on the End Cap

  9. Wipe off any excess silicone from around the edges.
  10. Picture of Wiping Excess Silicone

  11. Replace all six Allen head screws in the end cap. While you can start them, do not fully tighten them until they are all in place.
  12. Picture of Starting the Allen Heads

  13. Once you have started the Allen head screws, you can tighten them.
  14. Picture of Tightening the Allen Heads

Reassemble the silencer.

  1. Clean the quiet core with a wire brush.
  2. Picture of Cleaning the Quiet Core with a Wire Brush

  3. Place a small amount of high temperature silicone on the end cap. It does not need to completely cover it since it is used to dampen the vibration and isn’t used to actually seal it. Three small dabs should be sufficient.
  4. Picture of Placing Three Dabs of Silicone on the End Cap

  5. Replace the quiet core.
  6. Picture of Replacing the Quiet Core

  7. Place dabs of silicone between the two end pipes as well. Remember: This is used simply for a dampening effect.
  8. Picture of Placing Dabs of Silicone Between the End Pipes

  9. Replace the end pipe.
  10. Picture of Replacing the End Pipe

  11. Replace the cover.
  12. Picture of Replacing the Cover

  13. Screw the cover bolts back into place.
  14. Picture of Screwing the Cover Bolts into Place

Enjoy a Repacked Silencer

Repacking a silencer is not a difficult task. Now that you’ve finished, you can put the exhaust back on your quad or bike, knowing that it’s going to keep delivering the performance that you expect.

If you don’t already have some packing material, try out the Lexx MXe premium silencer packing used in this tutorial. It works great for both 4-strokes and 2-strokes.

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What are your silencer repacking tips? Let us know your tricks in the comments.

Technician Disclaimer