Debaffe failure- Updated,got'em out

[cajun2wheels]

I attempted to remove the baffles on my 05 1600.I had the video and written instructions and started by cutting the weld with a 1 3/4 hole saw.Got the weld completely cut and the baffle was loose. I could move it up,down,and side to side.After trying to pull it out with needle nose pliers without success we tried attaching a heavy duty dent puller(slide hammer)to a pair of vice grips.That did not work either.We made several more attempts by shaking,twisting and pulling.I then drove the bike several miles at 65-70 mph hoping the baffle would blow out.No such luck.Does anyone have any suggestions?Am I the only one that could not get the baffle out?

[ringadingh]

Sometimes they can be stubborn to remove, Id keep trying with the slide hammer, thats probably your best shot.

[cajun2wheels]

Originally Posted by Ringadingh

Sometimes they can be stubborn to remove, Id keep trying with the slide hammer, thats probably your best shot.

I used the slide hammer until the baffle metal started tearing.It almost feels like the baffle is attached to something on the other end.I don't believe it's carbon build up because the baffle has quite a bit of side to side and up and down movement.

[dabull]

keep at it;) my right side was a bear...i just kept twisting and pulling, she finally let go....vise grips the way to go btw ;)

[Cajunrider]

Steve, The opposite end of the silencer slips into the interior baffle. I saw this on mine with the other end being scratched all the way around up to a certain point. If you can get it to start turning it will slide out. Some can be very tough. Grip it tight with a pair of vise grips and just keep try turning it while tugging and it will eventually come out. Good luck.

[cajun2wheels]

I won't give up Mitch.My buddy is putting together a tool that will slip inside the baffle and expand.We will attach it to the slide hammer.He said the harder you slide the hammer the tighter it will grip the inside of the baffle.I'm not sure how this works but he is very good at this type of thing.I did try to twist the baffle but the metal distorts.We are going to start fresh tomorrow.We have not ruled out explosives.I will keep you advised on our progress.

Note:I keep saying baffle so now I know it is a silencer.

[cactusjack]

That baffle has been in there for 6 years and probably has significant carbon built up on it that it won't easily come out. It will come out and it sounds as though you are on the right track.

[heychap]

I had the same problem with one of mine. Loose as goose but will not come out. If I remember correctly I was using an old hole saw and I went to Lowes and bought a new one that may have cut deeper, and it came out like butter. Keep trying...We're pulling for ya...:)

[mrfuni]

I had the same problem...Finally gave up. They're still in there and maybe one day they'll shoot out like a Torpedo on the interstate. Still the sound is better so all is good.

[Top Cat]

Note to self, do not follow Joe on the interstate.



cajun2wheels , are both baffles loose but not coming out?

[cajun2wheels]

No,we only worked on the right baffle.I figured if it didn't come out I didn't want to cut the left side and that baffle come out. I don't want to have one in and one out.

[macmac]

Aye capt, thars a soccor mom in a mini van dead astern! Dive Dive Dive, fire the aft torpedos Fire 1! Fire 2!

[redjay]

Get a 18 inch length of threaded rod the same thread as the bolt in the vice grips. Get a piece of bar with a hole in it (or a big socket), put it on the threaded rod with a fender washer and nut and use the vice grips like a slide hammer. Keep your fingers out of the way !!!

[macmac]

Or buy a OTC vise grip slap hammer. Red I think you left out the slap hammer weight... right???

Or is the 'bar/ socket' the weight?

[mobandy78]

I have an 05 1600 and took my baffles out. I used a 2" or 2 1/4" hole saw from Lowe's, can't remember which size exactly. But the bigger hole saw worked great for me. Silencers slid right out when I broke through the welds. I'll check this evening when I get home to see what size I have and report back later. ::)

I believe I saw a post where the silencers in the '05 have a larger diameter towards the center of the silencer than what is at the rear (where you drill through). This may be why you can't get the silencer to come out of the pipe. Of course, I could be wrong about that. ???