I'm have a small dilemma in trying to repack my Rossier. I have drilled out the rivets and the insert is not wanting to come out. I put my disc setup back on the end of the pipe and then inserted a large dowel into the front of the pipe and rapped on the disc endcap from the inside hoping that it would break the whole insert loose but still no luck.

I could ride it until it breaks loose i suppose, but that is not my preferred method.

Any input???


Ken K

just did mine a couple weeks ago, and it was way time to do it too.. the fiberglass was kind of burnt in/ stuck to the sides. it was a pretty big mess.

Had the same problem. once the rivets were out I tried using a flat head screw driver to tap out the core from the other end of the cap.. didn't work and I didn't want to push the issue and screw anything up.

I sprayed a little WD 40 around the end cap area "after" taking off the disks( let it sit for a bit). the core sat about 3/16" in the muffler so I got a 2X4, held the pipe up and smacked it on the 2X4 a couple times till the core moved to the end of the muffler.. then It seemed to work it's way loose with a little tugging..

I had thought that taking the core out was the hard part. Lining up the core after repacking was just about Hell.. ended up being a two person job.. I might have wrapped just a little to much fiberglass on. LOL

But it works and sounds great now..

Wear LONG SLEEVES AND GLOVES.!!!!

Trust me on that... I didn't think about it, till it was toooooo late, I still itch to this day.

Good Luck.

You can also do machine screws in place of the rivets just make sure to silicone the screws before tightening...I have done this with other exhausts with great outcome and less hassle of rivots and quicker to repack....Just make sure to use aluminum or stainless screws...JMO...

Those are both good ideas. I'm open for a few more :)

I would like to know what packing last the longest ?????????????????????

pillow packing last the longest.