Motorcycle Muffler Repacking Explained and Made Simple by Yoshimura R&D

Take a look at what it takes to repack a Yoshimura muffler. It takes the right tools, the right amount of packing material and of course a whole lot of patience. In this video we guide you with some of our tips if you are so inclined to do your own repack.
Don't think you have the right amount the above? No worries give us a call at [phone] one of our Customer Service reps can guide you on how to send your muffler in so the pros can repack and renew it for you! you can always email [e-mail]

[@angrygnome4779]

Wow the fact that this manufacturer is will to share this information speaks volumes for this company. I’ve got yoshi’ on my Aprilia and it sounds awsome.

[@YoshimuraUSA]

Thank you!!!

[@BlockchainToTheFace]

@@angrygnome4779 the only thing they shared is the discouraging of any individual to try this at home. Clearly a scare tactic to get your money. Like you need a “pneumatic” rivet gun, no, no you don’t.

[@dukatikiddukatikid7358]

I’ve dealt with the top blokes at Yoshimura,the customer service,pricing,parts availability and advice is top notch. Cheers from Australia.

[@YoshimuraUSA]

Cheers!

[@Ladosligese]

this shows why Yos is the only brand of exhaust i run .. service is top notch

[@hazimreitz]

When a company gives you tips about on what to look for if you need to repack is just like how old youtube does things, no bs and straight to the point. I wouldn't know what to look for even if I tried and would think "Oh dude, look at my titanium esq muffler so cool" 🤣🤣🤣

[@BugzeeSiegel]

I just spoke with Monica on the phone like 30 minutes ago… wonderful customer service!!! Nervous to do this to my trc but I’ll get it all ordered and I’ll get it done. Thanks guys!!!!!

[@YoshimuraUSA]

Thanks for the kinds words. We appreciate it!

[@denislainez8572]

@@YoshimuraUSA send me address and phone number please I’ll be sending my exhaust to you

[@Keith-l2s]

Absolute quality work.

[@jaszkowaenduroteam9013]

i'm an akrapovič user, but i really respect you guys for making professional guide on how to repack your exhaust, and i really appreciate some details you mentioned because not all videos on repacking exhaust mention those small details that are important btw even thought im akrapovič guy i really love your exhausts, yoshis on sxf’s 450’s are just amazing :D

[@YoshimuraUSA]

Thank you so much! I hope we can win you over one day to our systems!

[@jaszkowaenduroteam9013]

@@YoshimuraUSA i'm down for trying new things so it is really possible that i'll try your exhaust system one day 😁

[@3406Accert]

Pop's I'm sure would approve & the final end cap high temp sealant shop trick with a very thin layer of material looks like a pastry chef decorating a Wedding cake with high real ingredients icing. I'm a very good Used 2000 RS-3 Carbon fiber body bolt on today from Ontario for $185+ shipping and planning on shipping Yosh pipe to you guys for a Repack and road rash repair end cap on the mid pipe location and watching this I'd prefer the pros to do it & she will come back looking & sounding like new Again with the proper weight of repack material. Thanks for the video it's definitely a rewatch over & over again for me, Plus Kevin Swantz is one of my favorites pro riders ever in the Non robot IMU bike era on the 1980's till he retired.

[@enzo6sixty]

Just installed the Yoshimura R77 full exhaust on my 2020 Yamaha MT-03 and I love it!

[@JimOutofControl]

Any rivet gun will do. And this info is available anywhere. This is an easy job.

[@Black_Forest_Gixxer]

I have a Yoshimura obsession. Everything on my Gsxr has been converted to Yoshimura. I just think it's a shame that the Yoshimura tri Oval Dual Exit for the Gsxr 1000 K7 is no longer being made. I've been looking for one for ages. If you still have one, I'd buy it straight away :)

[@YoshimuraUSA]

What about this? www.yoshimura-rd.com/products/builder-series-tri-muffler-kit-95sxx111700?variant=40551187808359

[@mikeb4708]

Being able to send it back to Yosh to have it repacked is a great benefit! Makes me wish I had purchased Yoshimura exhaust for my KTMs

[@tom24gr46]

Great video! Is a pneumatic rivet gun absolutely necessary or can I get the job done with a regular manual rivet gun?

[@YoshimuraUSA]

pneumatic is better and is going to make your life so much easier. It pops the head of the rivet crisp. They are not that expensive...

[@easternyellowjacket276]

Nice video. Unfortunately, I can't get the exhaust apart on my dirt bike. Can't even remove the muffler. Any tips or tricks on getting this thing separated?

[@YoshimuraUSA]

give us a call we can give you some tips 800-634-9166

[@easternyellowjacket276]

@@YoshimuraUSA Finally got the muffler off. All set, thanks!

[@John_Doe_6996]

Would a cheap manual rivet gun work, if used with yoshi recommended rivets?

[@Two_wheels_dasher]

I have a full system yoshi on my 2017 grom since day 1, it has 48k miles, I think it's time to send it for a repacking.

[@YoshimuraUSA]

When you are ready, we are!

[@sun6v546]

Gud jaab , Mite . Cheers from india.

[@Ifelta]

I have pulled and repacked 3 times and its louder now than when I started. I'm going to ship it to you.

[@YoshimuraUSA]

Good call!

[@Kevin.OBrien44]

is it supposed to be quieter?

[@YoshimuraUSA]

@@Kevin.OBrien44 as a general statement, yes!

[@NateDizz09]

Great tech tips. The yoshi revits on the website came in clutch. Back in action..braaap!

[@KyleP8325]

@Yoshimura R&D of America, Inc. In response to another comment you mention that the rivet cannot be properly installed by a hand riveter and can only be properly installed by a pneumatic riveter. Why is that? What do pneumatic riveters do differently than a hand riveter?

[@YoshimuraUSA]

A commercial hand rivet gun will work fine… most local hardware stores don’t offer that option and instead sell light duty rivet guns that are suitable for aluminum or small 1/8 “ rivets. If you can manage enough grip strength to pull a 2/16 stainless rivet with a standard manual gun I ihave yet to see on not destroy the jaws by either stripping the gripping ridges or outright breaking the mandrels. The pneumatic guns sold at places like Harbor Freight have plenty of HP to pull the mandrel and are durable enough for occasional use.

[@crawfordd17]

@@YoshimuraUSA which brand of pneumatic rivet guns were you guys using in this video? I noticed 2 different types. Thanks!

[@YoshimuraUSA]

@@crawfordd17 The brand doesn't matter, the consistency and ease of pulling the stem of the rivet is key.

[@MotoVolksTube]

I have a Yoshimura in my KLR650 and I love it. Wondering if I can add one in a VW Rabbit 1.8 and be good???

[@mxgryan]

Great info guys.

[@YoshimuraUSA]

Thank you!

[@davidpirro1326]

Great video, very helpful. Are you able to install closed end rivets using a hand riveter?

[@YoshimuraUSA]

Not correctly.

[@davidpirro1326]

@@YoshimuraUSA Okay thanks for the clarification, are there different kinds of rivet guns or just pneumatic?

[@YoshimuraUSA]

@@davidpirro1326 Pneumatic is the best way. Harbor freight is a cheaper option. Home Depot, Lowes al have them.

[@davidpirro1326]

@@YoshimuraUSA Awesome, thanks so much for the help!

[@A_Pt_9298]

@@YoshimuraUSA And what about those drill bit riveters?

[@4bearsi678]

I’ve owned more than 2 dozen aftermarket exhaust that had threaded fasteners used and have NEVER had them fall out or came loose! However they are much better in design and easier to service! There’s a reason custom performance companies like Muzzy, Graydon, Micron, CT Racing, EMPIRE, HMF, Rossier, Barkers etc Us threaded fastners! They are the best! However I have had a yoshimura end cap come loose

[@ronaldofreires]

The best Yoshimura 💪💪

[@250txc]

Very good video and thxs for explaining some of the specific points along the way...

[@YoshimuraUSA]

Thanks for watching ...and learning!

[@charlessmith6486]

I just purchased a Honda African twin with a RS-4. This exhaust is way too loud for me. What do I need to do to quieten it down to a more reasonable level? Thx

[@YoshimuraUSA]

We make a spark arrestor for it. SA-19-L that will decrease the dB nicely!

[@justinelliott4127]

What kit will I need for the RS-4S full exhaust for my '13 Ninja 650?

[@HighGrade_FireBlade]

Do you need a pneumatic rivet gun or can you use a manual rivet gun?

[@YoshimuraUSA]

Pneumatic will save you a lot of headaches and is a better tool for the job

[@HighGrade_FireBlade]

@@YoshimuraUSA what about a battery powered riveter?

[@YoshimuraUSA]

@@HighGrade_FireBlade never used one.

[@raredesign]

Great tutorial! Thanks guys.

[@daveyt4802]

What is the quietest packing for my muffler??

[@YoshimuraUSA]

The kit that is spec'ed for your bike

[@vancouver6756]

Can i order directly for my xr200? Living here in the philippines

[@flipmafioso1851]

Hey i have a 2019 drz400sm i already have a yoshimura exhaust rs2 on it but its damage...i got an offer on a drz650 yoshimura exhaust..so I'm asking can the slip on work with the pipe from the drz400sm

[@YoshimuraUSA]

please call us 800-634-9166

[@jonathanhardy4626]

Do you guys work on cans that have been cut down, just purchased a used bike and I like it loud but it's a bit too loud yet I could not do this job myself, please let me know

[@YoshimuraUSA]

We don't work on and we cannot recommend cutting down the canister.

[@jonathanhardy4626]

@@YoshimuraUSA ok, thx for your reply

[@florrevansteenkiste]

I just bought the repack kit for my TRS , and I weight the exact grams for my 18” BUT it’s pure white filling and my question is if I putt it in with a screwdriver or can I first wrap it around the metal sleeve first ... Cause there are no videos available of the material that yoshi send over to customers 🤷‍♂️. If you take a look at the original filling , it’s prepacked and easy to install , why is that not available ? Much Easyer then a bag of filling material

[@YoshimuraUSA]

Yes you can use a screwdriver, but we would recommend something a little more blunt like the end of a broom handle etc. That packing that was installed back when your muffler was made is no longer available.

[@florrevansteenkiste]

@@YoshimuraUSA thanks for the reply but I was wondering if there is a possibility to get in contact with one of tech guys who can assure me that I did it the correct way cause I’m not convinced that it’s done properly , if feel less resistance in the muffler and more pressure but still feel vibration from the aluminium housing when I rev the bike 🙄

[@YoshimuraUSA]

@@florrevansteenkiste maybe its better you send to us for repacking...call us 800-634-9166

[@joshuajutz6747]

I know you arent supposed to gut these. I bought a new RS-5 a few months ago. I really love the look and the brand. The sound is good! But a little quieter than I was hoping for. Is there a good way to make these a little louder without removing the packing?

[@YoshimuraUSA]

You can remove the sound insert.

[@cultofeyes7260]

I've seen people cut them down in length and put the end of the can back on, it won't be an insane amount of change but it'll be a bit louder.

[@YoshimuraUSA]

@@cultofeyes7260 We completely do not recommend cutting your muffler down.

[@cultofeyes7260]

@@YoshimuraUSA naah its a great idea 🤣

[@A_Pt_9298]

Erm, remove the baffle?

[@kimarellano8952]

What kind of fiber you used? Do u recommend me use a fiber clothe used for making a fiber glass?

[@YoshimuraUSA]

We sell kits with the correct packing product and the correct amount amount of packing product. www.yoshimura-rd.com/collections/replacement-service-parts/repack

[@OutbackOntario]

great video guys

[@rstephen001]

Was told to use 2.1lbs of packing for my 2022 yz250f rs-12 muffler. I weighed that amount and put it in but there is about an inch gap of space left. Is that normal or should the whole exhaust be packed all the way to the top?

[@YoshimuraUSA]

If you follow the instructions with our repack kit you will know (if its the correct kit) that you packed the muffler to tight. Give us a call if you need help. 800-634-9166

[@rstephen001]

@@YoshimuraUSA Followed your instructions but the thing is you dont sell a repack kit for a 2022 yz250f rs-12. Hard to buy the right kit if you don't sell one. So I was told by your sales to buy a different one that came with 2.5lbs of packing and to weigh out 2.1lbs. Of course this kit also came with exhaust graphics fthat is different and doesn't look the same as the rs-12. No mention anywhere in the instructions about packing it to tight so how would I know if I packed it to tight? After emailing customer support they told me to just add more which sounds like now was the wrong thing to do. Dont know because you didnt answer the question. It would have been nice if you just answered the question instead of implying I did something wrong and bought the wrong kit and didn't follow instructions. Now I am worried it is packed to tight after following your supports advice. So I am going to ask again so if someone else has this problem they will know the answer, is it normal for that inch gap to be there if I weighed out the correct amount?

[@YoshimuraUSA]

@@rstephen001 The packing kit that is for your bike is here docs.yoshimura-rd.com/REPACK-RS12-MX.pdf and contains 2.2lbs of packing material as well as hardware and decals for the most current version of your muffler. Note: Your system was originally packed with 2.1lbs of the same material. We do recommend in our instructions to use the whole amount of material which is less that 5% over... This is a negligible difference to overpack and really only adds a couple ounces of weight and increases durability. From experience we can say its easier to pack a system too tight than it is to pack it too loose. Too loose leaves you with extra material, too tight leaves space when you are done, and neither are ideal. For the best results we recommend you remove the packing and re stuff the muffler evenly adjusting the density of the packing to finish the job with the packing evenly distributed from the front to the back of your muffler's sleeve. Hope this helps. If you have any other issues please call in and we will try to fly you in for a safe landing...

[@rstephen001]

@@YoshimuraUSA Thank you for the response. Not sure why I was told to buy the adv kit by your sales guy Don then. You also need to update your kits information on your website to show which kit is for yz250f. Currently even that mx kit does not list the yz250f as a bike that the kit is for which I'm guessing is because it technically isn't. It is already put back together so I am not going to rebuy another kit to get new rivets that I would need to repack it again. It would be nice if you sold a kit that came with the correct amount of packing for the yz250f, would have been a lot less hassle and confusion. It seems like the rs-12 for the yz250f was an afterthought with it being literally the only bike that doesn't have its own repack kit and your sales people giving out wrong information on what kit should be used for it.

[@atxjax1]

What size are those rivets?

[@retribution999]

Are these road legal from a noise and emissions point of view?

[@YoshimuraUSA]

yes.

[@karloz7386]

I have a damaged carbon end cap what do it do ? It’s for a 2014 crf250r

[@YoshimuraUSA]

We can fix it or you can fix it. www.yoshimura-rd.com/collections/muffler-end-caps

[@rodneyhoskins8187]

Does the muffler Get Louder if it needs repacking?

[@YoshimuraUSA]

Yes it does!

[@techmalayaly7562]

What happent when we insert much ceramic wool, plz reply is anybody knows the answer

[@GENX80.]

If i want a repack and have a dent could they fix that too?

[@YoshimuraUSA]

depends on the sevarity of the dent. If we cant fix it we can put a new sleeve on it!

[@GENX80.]

@YoshimuraUSA I tried reaching out directly by email but DON won't respond back ...I see no sleeve kit on the website

[@YoshimuraUSA]

@@GENX80. we don't have sleeve kits per se. It's a part number in our list of components. Call us and talk to Joyce. She rocks!

[@GENX80.]

@YoshimuraUSA already got it mailed off DON pulled through

[@kalebschaben6837]

What is average cost to have exhaust repacked by you guys

[@maximusmax4557]

One MILLION dollars!

[@owenbell2572]

Thank you so much for the video guys! You rock. I have a Shorty Off-Road Model from you guys. It is very loose and wobbly. Would a repack fix that? The metal base of the exhaust tip is very sturdy but the rivets seem very loose and so does the carbon and the rest of the exhaust after the first rivet band.

[@maximusmax4557]

"Massage the end cap off." I've always referred to pounding something off or pounding something loose with a BFH as "persuasion."

[@ngouco9916]

Hi, I'm from Vietnam. I am a big fan of your products. I want to chat with you on social media, to learn more experience and buy some items. looking forward to learning. thanks!

[@YoshimuraUSA]

We have a distributor for your country. www.yoshimura.asia/

[@Smallbore2wheels]

Good info. Thanks guys

[@shehabaldeen1009]

If i want to make the muffler louder can i insert a bit less packing than recommended?

[@YoshimuraUSA]

if you run less packing it will heat up the components inside the muffler and compromise them. We would NOT recommend this at all!

[@Tyler_Mayhem]

This is a great video. Thanks guys

[@YoshimuraUSA]

Glad we could help!

[@zairintube]

For Cb650f which one the best

[@YoshimuraUSA]

www.yoshimura-rd.com/collections/all/Honda-CB650F-2018

[@Califunk]

What's the downside to removing all the packing besides being really loud ??? I've ran into a few riders on the streets who removed all the packing out their mufflers left them hollow?

[@YoshimuraUSA]

Besides your bike not running right, it being loud as heck and the muffler could literally explode no downside.

[@curtisgarcia5732]

So what is the price range for repacking? Curious to know,because on my cbr1000rr my yoshimura r77 exhaust does not sound the same anymore, before it had the deep sound, know it's like no depth to it

[@YoshimuraUSA]

Give us a call and we can get you a quote. 800-634-9166

[@rambobaizz1930]

I plan to repackaging fiberglass on my yoshi rs-2 on my klx250s...any dealer malaysian that i could refer?

[@YoshimuraUSA]

We recommend using only Yoshimura components.

[@Wreckhouse69]

This is only worth doing yourself if you have the equipment available to use. I live in Los Angeles. No fuckin way I'm doing this at home i wish

[@eatcommies1375]

Did mine, ❤️it, Like brand new now

[@zairintube]

What the diffrent r77 r55 r11

[@ratbrain7743]

Do I have to have a pneumatic rivet gun for this?

[@YoshimuraUSA]

Absolutely!

[@1kory883]

Hell no you don't, manual rivet gun achieves the same thing. Really guys !

[@ratbrain7743]

@@1kory883 I did mine with a regular rivet gun and hardware store rivets 20k miles ago. No problems

[@BhanFor2]

Currently have the RS-5 for my 2007 Cbr600rr. I recently looked into your website, and was noticed that you guys have an office in Chino, CA? Will it be possible for them to do the maintenance? Not tryna pay for shipping...LOL

[@YoshimuraUSA]

Yes please call us and get an RMA number, that way when you drop off we can get you in and out quicker. 800-634-9166

[@daveyt4802]

Great Vid! Trying my Akra can. Can't get the front cap off, looking for tips.

[@YoshimuraUSA]

good luck!

[@daveyt4802]

I got it off. Job is done. Nice tip about the weights.

[@guitojs]

Can I use aluminum closed rivets on 2 stroke silencer? What is the size of the rivets?

[@YoshimuraUSA]

We don't make 2 stoke silencers so we cant say...

[@christophermcglynn3838]

Can you take the baffle out ? Or the silencer on my rs5

[@YoshimuraUSA]

yes! Call us with any questions

[@philinit6476]

I'll go ahead and do that myself said no one ever after watching this video 😂

[@YoshimuraUSA]

LOL!

[@quietfrog7046]

Yeah I think I will do it

[@Jmoney92591]

Easy

[@maximusmax4557]

I've been a certified motorcycle tech since the middle 90s, and currently own my own cycle repair shop. "I'll go ahead and do it myself." 😁

[@RobertVDN]

How do I determine how much packing I need to put into my stock YZ250F muffler? It isn't in the manual. Do I weigh the old packing and add roughly 100 grams or what do you guys suggest?

[@YoshimuraUSA]

We have specific weights for each bike and muffler. Call our office and we can give the amount needed.

[@MrAB-ez3ry]

Hi for malaysia u can fix it i got 1 exhaust Yoshimura for yamaha 135cc

[@ciaoitalo]

I want that dude on the left's hat so bad

[@YoshimuraUSA]

Sold out!

[@rodericktasin3831]

How to achieve deep bass sound for mufflers on single cylinders?

[@YoshimuraUSA]

Use the Alpha!

[@robbietucker7815]

Interesting thanks

[@paulhetherington3854]

Hence; a sleeve-- easily gets-- twisted bent vibrato, i.e. reverbs - spider cracks.

[@The4strokelover]

Does this also go for 4-stroke mufflers?

[@YoshimuraUSA]

yes

[@waylonlegend4603]

I’ll do it myself. Thanks.

[@moslimislam5714]

Alright guys, you heard what he said. Rubber side down.

[@YoshimuraUSA]

haha!

[@jamesbowman5062]

My wife is going to hate when I show my son how to repack his own, and then mine.

[@ratbrain7743]

I'm sure everybody has a gram scale

[@YoshimuraUSA]

You can use Google to convert the weight...

[@rockyp3917]

There is absolutely no reason to have rivets instead of screws. The whole idea seems to be an ongoing maintenance cost. Kind of like a membership.

[@YoshimuraUSA]

We have been doing it wrong all these years :(

[@mightyboomerang2932]

Yosh 💪

[@eatsleepplayrepeat]

Not user friendly. FMF can be taken apart with common tools.

[@88Heckenlively]

My 690sm Arrow exhaust sounded great - 8k miles later it sounds ridiculously loud and clapped out. I feel sorry for my neighbors in the morning. I'm that guy with the stupid exhaust that sets off car alarms. Moms hear me coming and snatch their children and run for safety in parking lots. Ugh.

[@YoshimuraUSA]

Bummer!

[@riotgear9116]

Definitely dont need a pneumatic rivet gun.

[@YoshimuraUSA]

Certainly makes the job a ton easier. Popping the spec rivets need to be tight.

[@_nikk0]

Yeah exactly

[@213spaceforce]

you need to pack sum muff

[@fakexmr6637]

Why does he look like negan from twd tho lmao

[@lucassturgin8710]

I don’t think many people listen to half the shit said in this video

[@YoshimuraUSA]

That's for sure! We see a lot of burnt out mufflers that do not get proper maintenance.

[@lucassturgin8710]

Yoshimura R&D of America, Inc. I pulled mine off my fourwheeler and 90% of the packing was gone

[@YoshimuraUSA]

@@lucassturgin8710 better repack it or get it in to us!

[@lucassturgin8710]

Yoshimura R&D of America, Inc. I already repacked it

[@azrifadly4378]

why does that guy look like negan from the walking dead 😂

[@YoshimuraUSA]

It's him!

[@MattyS7777]

Orrrr, just buy a new one. Awesome video, but guys like me have no time for this shit unfortunately.

[@Ryderknoblauch509]

I'm just gonna use screws

[@YoshimuraUSA]

We don't recommend that. that will void any warrantee as well.

[@codyray8754]

Do not do this! Once they said remove the rivets I was like wtf you need those there's better videos forsure these guys will mess up your muffler

[@YoshimuraUSA]

We have built and rebuilt countless mufflers over the course of almost 70 years in business, interesting we would "mess up a muffler."

[@codyray8754]

I just did 2 of my bikes DO NOT TAKE OUT THE RIVETS

[@jamesnorth7318]

@@codyray8754 then how the hell did you pack it?

[@codyray8754]

@jamesnorth7318 you can get a rubber mallet and you can knock it loose and you slide it back together it's alot simpler than this dude trying to make it. Just look for another video bc I didn't have to do none of this

[@MiguelMorales-ch6xl]

Yoshimura power