Bulk Instructions Simple
To get the most life and performance from RaceTEX bulk muffler packing, a mu ffler should be repacked with the core in it. Ideally, you would like to fill the front of the muffler first (the end closest to the engine) and work towards the exit. This isn’t always possible as with mufflers that have cores welded to the rear end-cap (Honda CRF150R, White Brothers E-Series for example).
Step 1 – Muffler Disassembly
Before removing any fasteners, it is a good idea to make some marks on the shell and end-caps that will remind you how to orient the end-caps during reassembly.
If one of the muffler’s end-caps has threaded fasteners, remove them and pull out the end-cap that they hold in place. If the core is still in the muffler go to Step 2. If the core is attached to the end-cap that you just removed, remove the other end-cap and re-install the core and the attached end-cap.
(Tip: If sealant is visible where the muffler body meets the end-cap, cut through it with a razor knife to break its bond.)
STEP 2 – Packing Installation
Push small amounts of the into the muffler cavity spirally around the core. Use a blunt tool like a ruler or dowel to tamp the packing into place.
Important! Make sure that the front of the muffler (closest to the engine) is completely filled with no voids before continuing to fill the rest of the muffler.
Continue to feed and tamp one handful of packing at a time into the muffler, working your way around the core. As a rule of thumb, the density of this packing for a two stroke should feel similar to the density of a new foam air filter. For four-strokes, the density should feel more like seat foam. The density of the packing must be uniform throughout the muffler for maximum durability and noise reduction. Specific density information can be found on the reverse side of this sheet.
DENSITY RECOMMENDATIONS
For maximum durability and noise reduction, the recommended densities are:
Two Stroke Engines – use ą160 grams of packing per packable liter
Four Stroke Engines – use ą210 grams of packing per packable liter
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