Repack original mufflers?

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19 Jun 2014 17:03 #637218 by TheForumTroll
Repack original mufflers? was created by TheForumTroll
I was going to repack my original mufflers but looking at them it seems like a closed system. Is it possible to take them apart or are they indeed a closed system?
-[ KZ700-A1 '84 ]-

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19 Jun 2014 18:26 #637225 by MFolks
Replied by MFolks on topic Repack original mufflers?
Pictures will help, who made the system? On most of these, drilling out the pop rivets, re-packing the muffler & re-installing the rivets, is about all you'll need to do.
1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)

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19 Jun 2014 19:04 #637228 by TheForumTroll
Replied by TheForumTroll on topic Repack original mufflers?
Kawasaki I'd guess since it's original. So removing the rivets is needed, I see. It does have replaceable packing though right?
-[ KZ700-A1 '84 ]-

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19 Jun 2014 19:16 #637230 by MFolks
Replied by MFolks on topic Repack original mufflers?
Most do, usually fiberglass. You'll need gloves to handle this stuff. When I repack my bike's system (a Kerker K2S), I get the packing positioned around the baffle, and place at three places some 0.032" SS safety wire. It keeps it on the baffle better than masking tape does.
1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)
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19 Jun 2014 19:19 #637231 by TheForumTroll
Replied by TheForumTroll on topic Repack original mufflers?
Thanks. I'll get some rivets and have a go at it.
-[ KZ700-A1 '84 ]-

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19 Jun 2014 19:20 #637233 by MFolks
Replied by MFolks on topic Repack original mufflers?
To remove the rivets, you'll need 1/8" diameter drill bits, a 1/8" pin punch, hammer, and replacement rivets. If you don't have one, you'll need the pop rivet gun rivet . I think Harbor Freight has the rivets and gun. If no luck there, go to the nearest hardware store and ask them.
1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)

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19 Jun 2014 19:27 - 20 Jun 2014 05:51 #637234 by martin_csr
Replied by martin_csr on topic Repack original mufflers?
I could be wrong, but the stock mufflers may not have fiberglass packing.
I think there are a series of tubes & plates or something.

Here's a photo from a factory service manual posted by 650ed over at the KZ650.Info site.

KZ650-B/C
313
1981 KZ650 Competition Sports and Road
Last edit: 20 Jun 2014 05:51 by martin_csr.
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20 Jun 2014 10:29 #637280 by TheForumTroll
Replied by TheForumTroll on topic Repack original mufflers?
Hmm, it doesn't look the same on the outside as the one in the picture but it might be like that. I've removed the rivets but that didn't do much as the back plate is stuck.
-[ KZ700-A1 '84 ]-

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20 Jun 2014 12:33 - 20 Jun 2014 14:50 #637295 by martin_csr
Replied by martin_csr on topic Repack original mufflers?
The 82 650 has megaphone mufflers (instead of the reverse cone type in the pic) & I'm pretty sure they are constructed similarly as in the photo. I'd guess most if not all KZ mufflers are made pretty much the same way.... just a guess. It would seem rather hard to believe that Kawasaki would use fiberglass and not provide for a way to change it out.
1981 KZ650 Competition Sports and Road
Last edit: 20 Jun 2014 14:50 by martin_csr.
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20 Jun 2014 14:43 #637315 by TheForumTroll
Replied by TheForumTroll on topic Repack original mufflers?
Yeah, it sounds like the same system then. As long as there is no maintenance needed it's fine with me. I'll just polish them a bit instead then :lol:
-[ KZ700-A1 '84 ]-

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