My muffler has about had it on my 2000 sportsman. i was going to repack it but it is one piece welded. i have given some thought to cutting the end cap off, repacking it and the buttoning it up with my welder. does anyone know what kind of baffling is used? has anyone tried this procedure? if i dont cut it open im going to be buying a new one anyways so i would probally do it just for fun at that point.

 

OEM mufflers do not need repacking as they dont use packing. They are usually just a set of metal baffles.