250-500cc 09 wr250 silencer repack questions

I got the endcap from the pipe end off and pulled out the old packing. Looks like the inner perforated tube is riveted in. I can't get the other endcap out. Is the spark arrestor also connected to the riveted part or is it just connected to the endcap? I was thinking of trying to tap it out from the inside so I could clean it. Any other thoughts on getting the rear endcap out?

I have a 300, so I think we have the same spark-arrested setup. I pulled mine apart and it's been a couple seasons now since I switched to an FMF can. I don't recall there being anything unique about getting it all apart but I'm sure some rather crude tools were used in the process of disassembly. As with most things, it was easier to get apart than lined up and back together. I believe there is an o-ring on the end-cap that make it a little bit fiddly. I am not 100% sure, but I believe the sparky was a separate piece and the rivets tied the muffler body, sparky and cap together.

Those O rings are definately a pain in the butt. I wrapped the fresh packing around an old paper towel tube, slid it in over the tube which wasnt coming out, then removed the paper tube. Nice and quick. RTV replaced one of the o rings that got mangled trying to get the end cap back on.

+1 Brad_0

The tube and spark arrestor are one piece and held in by the rivets. To remove the spark arrestor to clean it, you have to drill out the rivets. There is no reason to remove the end cap.

Using a paper towel tube was a great idea. I would have never thought of that. Worked great and made it quick and easy. After struggling to try and get the o-ring back in, I bagged it and just used RTV. Thanks.