Has anyone taken apart their Bayou 220 muffler and re-packed it ? I feel like since mine is almost 30 years old.. i want to re-pack it. I use it hunting and any silencing I can get would be great. I just want to know if its worth it or not, and if you can leave the muffler on to re-pack it or do you have to take the entire thing off first ? I have no idea how to open it up.

 

I would be very surprised if you can "re-pack" it. Most silencers are packed, then welded together at the factory. Fairly sure Kawasakis have "baffle boxes" anyway, without any packing in them.

 

The factory muffler is not designed to be repacked, but that doesnt mean it cant be done. If you have the tools and knowledge it can v done easily. Remove the muffler and cut off one end cap. These are welded at factory, the reason they were not intended for rebuild. Muffler case must ve solid to start with. Pull out old packing which is probably gone by now anyway, then add new packing and reweld cap.

 

Put up some pics and results if you tackle it, I have a spare laying around that I would probably tinker with if you get good results.