Was wondering if anyone ever fixed one without replacing the carbon as a friend of mine due to a standing drop has dented his on the weekend with a nice palm size dent in the middle but it has no leaks to the muffler. I was thinking body filer and repaint but he will lose the carbon look.

Is it carbon fiber wrapped? Just remove the carbon fiber and pull the dent out. Never done it and I don't care so much for looks.

http://i2.photobucket.com/albums/y5/cuongnutz/Ninja%20250/BC0505DC-09A1-4336-9126-DCAE91D1007D.jpg

It is carbon fiber wrapped looks a bit like yours with a big dent in the middle. I was worried that the fiber might crack I was thinking worse case filler and black temp spray paint.

You can disassemble the muffler by removing the rivets/screws. The carbon fiber is wrapped and glued onto the muffler canister. It's time consuming but if you have the time and patience, it can be done.

Will give it a shot. If it fails then option b filler and paint.