How-To: Repacking your DASA Exhaust

Thank you to SandJunkie for writing this article!

First remove the canister from the bike. Also remove the mid pipe section that is bolted onto the canister. I am assuming your using a Junkie DASA tool for the process...if not then just get the end cap off any old way you can...and we will see you in a couple of hours...

For the Junkie tool, insert the washer into the end cap



Now use your ring pliers to insert the snap ring



It should look like this



Now install the 2 piece Junkie tool



The end cap should pop out like this...use the ground because it seems to work better than a bench top

Remove and discard the old packing. Lay the new pillow on the floor and roll your inner tube up in it like so. Keep it tight...the packing will come over on the inner tube by about 3 or 4 inches...

Now pull the sticky tape off and roll the pillow into the tape

The inner core has a small and a large end...the large end goes into the mid-pipe end cap



Leave the core up from the end cap about 1/2" so you can get the opposite end cap to grab onto the core better. There is no correct way for the pillow to go in...just get it in the best way you can with the inner core as close to the center of the can...usually it's off a little but thats the way it goes.



Now use a pair of pliers to pack down the pillow so you can get to the end of the tube for the other end cap

Now install the end cap. Get the inner core to line up first then use a awl to keep the end cap in position while you use a RUBBER mallet to beat the end cap back on. Use the awl to correct your line ans you work your way around. The holes do not have to line up exactly but try to get them all close as you can. Use the mallet and hit the fins on the end cap to line it up.

Make it easy on yourself and use a drill or impact to re-install the bolts. If the holes do not line up then use a step up bit to drill out the hole.

Last step is to apply the stickers

And your done. Stand back and admire your work