DONE!!! DeBaffle problems

[v0lusia]

OK I used the hole saw and dowel method to debaffle my '03 1500 FI. The welds are cut and the baffles move around, maybe 1/8 of an inch side to side. I can not get the baffle to come out. I've wiggled and jiggled ( ) with a pair of vice grips, wacked the grips several times with a hammer, bent the crap out of the end of the baffle, but still no luck. What am I doing wrong? Is there another "level" of plate I need to cut through?

[cactusjack]

What you are removing is a tube that is slip-fit on the inner end. If your bike is older, it may have some carbon build-up that is hanging you up. I was able to grab the ends of mine with pliers and rotate the tubes back and forth and they came right out. Another trick might be to run the bike and heat the exhaust up, which may loosen things up a little bit for you.

A little slide hammer with a hook may be helpful to knock it out. You can fabricate something out of random junk or you can buy a little kit cheap at Harbor Freight. Very handy thing to have.

[v0lusia]

Originally Posted by caddmannq

A little slide hammer with a hook may be helpful to knock it out. You can fabricate something out of random junk or you can buy a little kit cheap at Harbor Freight. Very handy thing to have.

I had thought about that I haven't used one of those since we used to use them to pop ignitions I'll have to try to find one.

[v0lusia]

Originally Posted by cactusjack

What you are removing is a tube that is slip-fit on the inner end. If your bike is older, it may have some carbon build-up that is hanging you up. I was able to grab the ends of mine with pliers and rotate the tubes back and forth and they came right out. Another trick might be to run the bike and heat the exhaust up, which may loosen things up a little bit for you.

It's an 03 with 3000 miles (just bought it). I ran it about 150 miles after I sawed the welds hoping it would vibrate loose but no luck. Sounds like I need the dent puller or more "wiggling" patience.

[Top Cat]

I had the same problem. You have to twist the bafflel clockwise then counterclockwise while pulling. they will let loose after a while.

[damark115]

I did it a couple months back on my 2000 FI. Pulling them was a pain in the butt. Patience and a couple beers. I used vise grips and a hammer.

[cactusjack]

Originally Posted by v0lusia

It's an 03 with 3000 miles (just bought it). I ran it about 150 miles after I sawed the welds hoping it would vibrate loose but no luck. Sounds like I need the dent puller or more "wiggling" patience.

Mines an 07 with 9500 miles, yours have been exposed to exhaust gases and temperature extremes a lot longer than mine have. Can you shoot some WD-40 towards the front of the pipe, the piece you're trying to remove is only about 8" long. Of course, it will smoke and stink like hell until the WD-40 burns off, but you'll be so elated at the new sound of your exhaust you aren't going to care.

[Yellow Jacket]

You also might want to try moving the baffle inward towards the front a little with a hammer and maybe a block of wood. If you can get it to move in a little that might break it free to where it will come out. Imagine a small tube going through a hole in a washer welded inside a lager tube. That's basically what the end of the baffle is doing. Just need to get it to move so it will pull out of the hole.

[v0lusia]

Finally got it done I sawed through the welds in about 3 minutes per side. But, I probably had 1 hour into wiggling/hammering/cursing the right side and 20 minutes doing the same on the left. BUT THEY ARE OUT!!!! Thanks for your help.