How to Repack Silencers for the YZ250
The Yamaha YZ250 is a lightweight motorbike built for motocross racing. It has a 249cc engine, disc brakes front and rear and weighs 227 pounds. The manufacturer's suggested retail price in 2011 was $7,150. The muffler system is not road legal and consists of a pipe filled with special packing that should be refilled every 30 hours of use.
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Things You'll Need
- 8mm socket
- Soft mallet
- Wire brush
- New packing kit
- High-temperature RTV silicone
- Clean cloth
Instructions
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1
Remove four screws from the front end cap with the 8mm socket and take off the front end cap. It may be necessary to tap the front end of the silencer with the mallet to get the cap off. Remove the old packing. If necessary to remove the old packing, remove the rear end cap.
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2
Take the muffler core out of the packing and clean it with the wire brush.
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3
Insert the muffler core into the end cap and slide the new packing kit over the muffler core. The new core comes with a paper tube inside it. Remove the paper tube. The muffler core should be an inch inside the new packing kit.
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4
Slide the muffler core and new packing kit into the silencer shell and push the end cap into place. Make sure the core is centered within the silencer shell and tap the end cap with the mallet.
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5
Apply the high-temperature RTV silicone to the seam between the end caps and the silencer shell. This will keep water out of the silencer. When the silicone is worked into the seam, wipe off the excess with a clean cloth.
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