your going to need repacking too.... i doubt you could change core and reuse the old packing....

here is the quiet core




here is the old stuff...

 

I just repacked my FMF on friday and i was cussing as well...partly my fault though.
I left the whole thing bolted up to make it easier.I removed the 4 allen bolts closest to the inlet side first....slide the whole can off to expose the core.I then drilled out the 4 rivets on the tip (outlet) end and removed the end cap insert.
THEN i reinstalled the empty can with the 4 allen bolts to the inlet flange piece that is still mounted to the bike.
NOW start packing.I use silent sport loose packing and i pull off large pieces and loosly wrap them around the core and push them in with a looong screw driver until seated.....don't pack too tight and don't pack too loose....this is the part with cussing.
after your done putting all that itchy scratchy crap in there just pop on the insert and rivet back on and then insert the quiet core and bolt on your end cap and spark arrester.....pretty darn easy except for the itchy crap.No sealer required as the fmf has o-ringed aluminum end plates for the can.I took loads of pics but i'm too lazy to upload,drag,drop and click....pretty bad eh?

 

ok going to try to answer a few questions... (if they were directed at me)
finger mullet first. Nope, i pulled it all out of the exhaust end. I was probably confusing you the way i worded it or something. or my lack of photography skillz.... but now that i think of it, it may have been easier to take off the other end? i dont know, i'm just glad its done with for a while.

Deej your next. I had to take the pipe off because i couldn't drill out the rivets with it on the bike, and you HAVE to drill the rivets to expose the packing. if you just un bolt the tip its just a tiny little whole with some sort of screen, guessing thats like a quite thing? i dont really know. i'd take finger mullets advice and call muzzy first and get the low down. because on the fmf packing it said take out the other end, not the exhaust end. stupid me, i like to read directions once things break, or after i'm done. haha figures.

Ems, not that you asked a question but i was lookin at the photos you posted and it looks like that packing went in no problem... right? mine was a like tryin to pack a clams ***, and thats water tight. It was so hard to get the packing in, that i had to keep ripping it apart just to ge the core back to the center of the pipe. I used all kinds of dowles to push it in and stuff. maybe its packed way to tight. but the old stuff looked like it was packed pretty tight as well. oh well... i guess i'll just have to ask the shop guy what he does next time i go down there.

oh and my dad says that it does sound a little quieter, noticeably quieter. so thats good, i guess its hard to tell when your sittin on it with a helmet on. good luck to all that are about to embark on this mission from hell. god speed.

 

Oh, I know I'll need to repack, as I've already planned on it.
Question for you: Big Gun says there are two different lengths of baffles. 15 and 17 inch.
Which one did you use? (I take it you have the EVO X?)

 

Glad I bought a Staintune.
Cost of repacking ..................................... $0
Time spent repacking ................................ 0 mins
Time spent removing fiberglass from hands .... 0 mins

[8D]

 

yes i have the evo x.... do a search on dirtsurfers ordeal about ordering a quiet core, and there was another guy who had problems... but you have to give them exact dimensions of your existing core, which is (should be) the same as mine, its the 15" one, your best bet is to call and order it on the phone, you need to know how big the "bell" end is, diameter and length.

https://www.kawasakiforums.com/m_90929/tm.htm
https://www.kawasakiforums.com/m_89153/tm.htm

 

OK...I put my pics up...so here is my story of my FMF which is really easy looking to do compared to what you did...I was just cussing from the airborn fibers making me itchy...but otherwise only took me 20 minutes to do.
#1 remove 4 allen bolts from inlet side

slide off the can.....of course this is after you remove the 3 allen screws holding in the end cap cover,spark arrester and the quiet core.

here is the items to be removed also.

Drill out the 4 rivets holding the end insert into the can.

re-install the empty can onto the pipe.
after you unpeel the old packing and crap.NOTE pic is not in sequence but you get the idea.




Grab a big bag of this stuff....Highly recommended from my local dealers guys that also ride SUMO and dual-sports....good power and keeps the noise down they say.

start packing away...not too loose and not too tight.....I used a loong screwdriver and my daughters ruler from her backpack....ssshhhhh... don't tell her ..LOL

the crap part.....

when you are packed to a T then you insert the end cover piece....FMF uses O-rings to seal it so it's easy.

The packing knocked the sound level down very good to where my air intake noise is alot louder from my seat than the exhaust.
The guys at the shop were correct....it works and works well.ok with me for 22$.....This is my input for the FMF.
NOTE: use a good high quality rivet for the end cap that does NOT pull the pin out of the rivet instead of breaking it off!!!! my first 3 rivets pulled the pins but the rivet was perfectly fine....I didn't think anything of it until i fired the steed up and exhaust blew out of the 3 damn holes without pins......drilled them out and slapped in 3 other higher quality rivets and all was good.

 

Yes Deej,I fixed the bent turn signal yesterday after i noticed it yesterday morning...LOL...I did all the work on the bike and never saw it...LOL...the wind blew my bike over in the driveway again last week.Just funny it took me almost a week to notice it.

 

race tools repacking is in a "pillow" so i dont get covered at all.... just wrap that around the core then push it all in together.

but its a real **** to stuff it all in there.

 

Priceless...........For everything else there's MasterCard[8D]