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Does anyone have any great tips on how to remove a Promotobillet endcap from a stock 250R exhaust? I don't see an easy way of doing it. Any help is appreciated.

Well after marring the heck out of the endcap and the can, I finally realized how to remove the endcap. The siilcone had made a tight seal and the endcap was almost impossible to remove because there is nothing to pull on. I tried prying between the endcap and can for over 30 minutes and never could get them apart.

I finally used some tiedown material and rigged it up like this. I put the rope around a post and pulled on the can until it popped free. After some sanding, both the can and the endcap edge looks better but not perfect.

Anyway, just in case anyone has the same problem I did, this is what to do to remove the endcap.

I like it!! But you should have been riding today instead!

So I am guessing your drilled out the rivets on the can that hold the end cap in? What did you to for assembly?

I just happend to pull the S/A out of my PMB last nite and had a small amount of packing around outside base of the S/A. Is this the factory packing on the S/A? I bought the full R exhaust used with the PMB installed.

Thanks!

steak, you're going to have to help me out with understanding your post...I don't quite understand the partial sentences. S/A means spark arrestor?

I did drill the rivets out first...make sure to use a drill bit large enough to drill the base out otherwise they rivets will spin and increase the hole diameter. Mine were 3/16". To assemble it, I used the hi temp silicone and placed the cap back in and riveted it back to the way it was....after packing it with new packing, of course.

It could have been the factory packing I guess?

Sorry about the poor grammer. S/A was in reference to the Spark Arrestor.

Thanks for the walk through. I think what I had found around the cone of the spark arrestor was some packing that was installed by the last owner to possibly keep some vibration or noise down. The packing is now in the trash and their does not seem to be any wiggle or play when it is all installed and tightened down.

I am not sure how often (hours) the packing should be replaced so I may just open the can up and do it for the heck of it.

Any recomendations on a brand of packing?

I just bought any old 4 stroke packing I could find. I doubt there's much of a difference as long as you make sure that you get 4 stroke packing. I bought Lexx 4-Stroke Silencer Packing at Rocky Mountain MX and had to cut of a few inches to make it fit. My stock packing had about 80 hrs on it...it was discolored but I'm not sure it was worn out. I just packed it for piece of mind. It thumps deeper now than it did.

It's tough to make sure all the packing stays in place when you put everything together..maybe some packing got wedged in the spark arrestor by accident or something. Sounds like you know what to check to make sure it doesn't rattle, etc.

I always have found it's easier to pull the opposite end of the can off to replace packing. The header end rather than the end cap. Wrap the packing around the exhaust tube, secure it with masking tape or tie wire, then slide the whole thing together. Use closed end blind rivets to secure the end back on the can with a little high temp RVT.