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Rik
Hello, new to triumphs andnew to this site. Just became owner of T509 speed triple 98 model. The bike came with a high level CF triumph exhaust as well as std. In my opinion it was just too noisy so I decided to repack it. My first task was to remove the 3 cap screws holding the rear stainless end cap. These were tack welded and corroded so only way to get them off was carefully drill off the heads. If they are stuck don't force them with allen key as they screw into mild steel standoffs tapped for 6mm screw and these will turn with the screw. I know I did it. Therefore had to turn 2 new standoffs and weld them onto can. Once the three screws are off, the end cap came off.
Then need to remove the 2 bracket 8 mm cap screws to get carbon sleeve off. Again I had to drill these heads off to get bracket off. Used penetrent and screw extractor to get the remaining threaded parts off. The Carbon sleeve then slides off. This now reveals ....... wait for it... A totally welded stainless steel sleeve. The carbon sleeve is only for show and is about 1mm thick. There is no way to get into the packing area without cutting and rewelding. I could poke the inside through one of the bracket holes and could see that there was not much packing in there. It needed repacking.
So what I did was drilled a 25mm hole just below outlit pipe at the rear usin a hole saw. This then allowed me to pull all the packing out using a hook (made from welding rod) and also used a hoover. I then filled the space back up with new glass wool using large screwdriver and butt of a golf club to push packing all around the baffle. I'ts amazing how much you can squeeze in there. Happy that it was full with no voids, I made a small plate to cover the 25 mm hole. This was oval shaped to allow two 3mm screws to hold in place.
Put sleeve back on (This didn't need to come off) and replaced end cap. Then tried ok. Noticed that it sounds quieter without that end cap on.
With all the tools, this can be completed in couple of hours.
The sound now is not so harsh. Now can repack by removing the 3 endcap screws, endcap and small plate.
Hope this helps....
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