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Discussion Starter #1 (Edited)
Sato Exhaust repacking

This is a how to for Sato exhausts but could be applied to other makes. But baffles in other manufacturers exhausts could be spot welded in place e.g Blue Flame twin port so take care

Tools needed:
1) Drill / metal drill bits
2) Rivet gun
3) New stainless rivets
4) Exhaust packing material (i used Acousta-Fil PTX Exhaust silencer packing, 1 metre length by 50 cm per exhaust
5) Gloves as it’s not the nicest stuff to use
6) Fishing line

1) I only drilled the rivets out on the exit side of the exhaust as there was nothing wrong with the outer sleeving so it didn’t need repairing or replacing, it is a struggle to get the end cap, baffle and packing apart from the exhaust sleeving as they are a very good fit but it will come eventually.

This is the left one coming apart


2) Slide off the old packing material from the baffle carefully as its not nice stuff to breath in or handle. (If it is the left one it will still be tightly fitted depending on when it was last done, mine was from new and around 10,000 miles old but the right as you can see nearly fell apart

The left one


Not much packing left on the right one as you can see



3) Wrap the new packing material around the baffle (taking note of how the baffle sits outside of the internal piece of the end cap. You will know what i mean when you see it.) Don't wrap the material too tight and tie it down with the fishing line which is just to keep it in place

It should look like this


4) Push the whole thing back together in the outer sleeving (this is where the fishing line comes in handy.)
Before trying to force the end cap back home fully just use your fingers in the opposite end of the exhaust and manoeuvre the baffle into place over the entry side of the end cap, this is where taking note in step 3 comes in (highlighted in red.)

5) When its all back together put the Sato emblem band in place using a rivet to hold it there then use the rivet gun and rivet everything back up, take care not to damage the exhaust whilst using the rivet gun as when the mandrel breaks off you are squeezing the rivet gun quite hard and you can have a tendency to jump/fall and damage the outer sleeving so i recommend covering the sleeving with a towel or similar item.

6) This is how the end result should look


Now refit them both to the bike after a good clean and not have to worry about having to repack them for another few thousand miles :grin2:
 

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I did this couple weeks ago....also replaced CF sleeves on the exhausts. I have a high mount scorpion Exhaust (full system)
 

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Fantastic post (4 years late to the party!)

Had a mis hap and something fell on my right hand can in the garage, got an ever so slight crease on the sleeve (can’t explain how much I cried after 12 years trouble free ownership!) which has been bugging me like crazy for the last 8 months!

Building up the courage to attempt this process myself and try and flatten it out. Do you think this is achievable or is there anywhere that will be able flatten the Ti sleeve once i have it off?
 

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Which brand exhaust? Ti is probably harder to work the kink out of then some other materials. I had pulled an older set of Yoshis apart to replace the sleeve. They actually offered new sleeves with a rivet kit. So you might want to check with the manufacturer also.
 

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Discussion Starter #5 (Edited)
Surprised the picture hosting site haven't blurred the pictures like they have done with all the rest of the posts, like has been done on other forums i frequent

Stick a wanted post up on this forum and hopefully someone can help with repairing the sleeve or even replacing it.
Would the sleeve from another manufacturer fit (as sato no longer make exhaust,) if you could remove the sato badge and rivet it onto as another sleeve. Just a thought
 

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Which brand exhaust? Ti is probably harder to work the kink out of then some other materials. I had pulled an older set of Yoshis apart to replace the sleeve. They actually offered new sleeves with a rivet kit. So you might want to check with the manufacturer also.
I've got Sato Low mounts, first thing i did was look to see if I could get a kit, but unfortunately not :frown2:
 

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Surprised the picture hosting site haven't blurred the pictures like they have done with all the rest of the posts, like has been done on other forums i frequent

Stick a wanted post up on this forum and hopefully someone can help with repairing the sleeve or even replacing it.
Would the sleeve from another manufacturer fit (as sato no longer make exhaust,) if you could remove the sato badge and rivet it onto as another sleeve. Just a thought
I've DM'd Duckhunter who has refurbed Sato's before, its such a slight crease that I'm wary of dismantling them and making things worse
 
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