bafflectomy help!!

[glenn]

I began the bafflectomy in my 2001 Nomad this morning. All went well till the part where you grip with pliers and jiggle and twist til it comes loose. The 1 3/4 hole saw is through and the pipe is free to wiggle at the tail pipe end. I have used all manner of pliers and vice grips to the point that the tail pipe is comming apart piece by piece with no release at the front. I stated the bike hopeing thermal expansion might help but no luck.
Any suggestions?

[dogdoc]

wow, not sure what to suggest now, good luck>

[fish]

some one said if you knock it in it will loosen up ???

[billmac]

Mine acted the same way on the right side. I think it was because I did that side last and the block of wood let my saw wobble. The baffle seemed larger than the hole.

But the problem was the hole was not round and neither was the baffle. So the baffle had to be turned to match the oblique hole that I had erroneously cut. I grabbed a pair of huge adjustable pliers and worked the baffle in and out very aggressively. Then I turned it a quarter turn and did it again. About the third or fourth time the baffle came out.

Hope this does you some good.

A slide hammer is the thing to use, but be careful. That pipe is attached to the engine on the other end, so if you really need to wail on it to break out spotwelds or built-up carbon & rust, take that muffler off the bike first.

[billmac]

One more thing. My bike only had maybe 200 miles on it. As an 01, yours may have more miles and a weld holding the end of the baffle. The weld could be from carbon or intentional. Maybe someone with an 2001 bafflectomy will set me straight. Good luck.

Now you have a good excuse to get some Vance & Hines! ;)


http://www.vanceandhines.com/b107_cl...-16_nomad.html

[kawgirl]

I had trouble getting the first one I drilled to come out. My bike is a 2002. I did knock it inward some then pulled on it again and twisted. It finally came loose. There was a good bit of carbon built up on it. Be careful not to hit in too far. You won't be able to get ahold of it.

I'm sure you'll get more suggestions to try. These guys are very helpful here.

[schoeney]

I wedged a pair of closed pliers (head first) into the baffle so I had some a good grip to twist the baffle....once I was able to twist the baffle it was easier to grip and pull it out. Good Luck!

[csguru]

I think i'd try running it a long time, get it good and hot to help expand the metal and then tap the baffle in towards the muffler a little bit.

[mncruiser]

20k miles on my bike when I did this and also my right side pipe refused to come out. Like you, the silencer was tearing apart so before there was nothing left. I had my teenage son sit on the bike and hold it from coming off the stand. I then used TWO vice grips, put my foot on the rear tire and pulled with all I had. The 2 vice grips was the key, using only one was pulling uneven and just tearing things up. Hope it works for you, I remember thinking what the hell am I going to do if I can't get this thing out.

[ells]

Hey Glenn. Hope you were able to get it taken care of. Looks like you got some good suggestions here. Welcome to the tribe, sometimes known as the Nomad Nation.

[ianicky]

Originally Posted by fish

some one said if you knock it in it will loosen up ???

+1

[glenn]

success!!
now if someone can tell me how to attach pictures to this reply, I would like to describe the "puller" that I made from some threaded rod and galvanized pipe. It wedges the baffle from inside and the pulls it by turning a nut on the threaded rod. No hammering or stress is transmitted to the engine or the bike.

Thanks for all the suggestions and support, I didn't feel as far out on a limb, not knowing what's going on inside the muffler.

my bike is baffled no more!

[papat]

Job well done on the baffles good luck on the picture post