Question about 1986 Yamaha RD 350

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How to get the baffles out off exhauts as it will not move with the bolt removed.

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Not much help mate but I'm assuming they are pretty well rusted in and REALLY stuck. (I had a similar problem on a 1976 RD 400).

Basically I had to use a hammer and chisel, WD40, Mole Grips and lots of hard work, then buy replacement baffles.

Good luck mate.

Posted on Mar 02, 2009

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1 Answer

Is it possible to remove the baffles on a 1984 Honda Goldwing 1200 interstate?


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Instructions
  1. Take Down
    • 1 Park the motorcycle on the kickstand or center stand and allow the exhaust pipes to cool completely.
    • 2 Refer to your Suzuki service manual and organize the metric tools needed to remove the baffle. On newer models, it may be necessary to remove the tailpipe section to modify the baffle. On older models, you may be directed to remove a bolt that secures the baffle in the tailpipe.
    • Follow the procedure given in the manual and remove the tailpipe section or slide-in baffle using the appropriate tools. Save any brackets or bolts. Place the tailpipe or baffle on a workbench.
    Tailpipe Baffles
    • 4 Hold one end the tailpipe up to a light and look inside the other end. Depending on the baffle, you may see very little light or none at all. Modifying the baffle is a matter of opening up areas in the baffle.
    • 5 Chuck a 1/4-inch drill bit in an electric drill. Use a bit extension if necessary to reach deep into the tailpipe with the drill bit.
    • 6 Place the tailpipe on a workbench. Use a towel or rags to prevent scratching the finish. Insert the tip of the drill bit into the tailpipe and drill a 1/4-inch hole in the baffle.
    • 7 Hold the tailpipe up to the light again. Determine the number of additional holes you want based on the purpose of the modification. Drill additional holes in the baffle if needed.
    • 8 Stand the tailpipe on end and tap it on the workbench to clear the debris from drilling out of the baffle. Make sure all debris is cleared out before reinstalling the tailpipe on the motorcycle.
    Slide-In Baffles
    • 9 Secure the outer end of the baffle in a bench vise with the baffle extending to one side. The outer end has the threaded hole where the bolt was removed to take the baffle out of the exhaust pipe.
    • 10 Measure the length of the baffle and divide it by four. You modify a slide-in baffle by cutting off a one-quarter section at a time using a hacksaw. Mark the baffle at the one-quarter point and cut the first section off the end.
    • 11 Reinstall the baffle in the exhaust pipe using the saved bolt and the metric tool.
      Start the motorcycle and determine if the modification produced the desired result.
    • 12 Allow the exhaust pipe to cool completely before removing the baffle for further modification. Most likely, cutting one or two quarter sections will give you the result you want. Avoid cutting too much off the baffle, or it will be useless.

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1 Answer

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Instructions
  1. Take Down
    • 1 Park the motorcycle on the kickstand or center stand and allow the exhaust pipes to cool completely.
    • 2 Refer to your Suzuki service manual and organize the metric tools needed to remove the baffle. On newer models, it may be necessary to remove the tailpipe section to modify the baffle. On older models, you may be directed to remove a bolt that secures the baffle in the tailpipe.
    • 3 Follow the procedure given in the manual and remove the tailpipe section or slide-in baffle using the appropriate tools. Save any brackets or bolts. Place the tailpipe or baffle on a workbench.
    Tailpipe Baffles
    • 4 Hold one end the tailpipe up to a light and look inside the other end. Depending on the baffle, you may see very little light or none at all. Modifying the baffle is a matter of opening up areas in the baffle.
    • 5 Chuck a 1/4-inch drill bit in an electric drill. Use a bit extension if necessary to reach deep into the tailpipe with the drill bit.
    • 6 Place the tailpipe on a workbench. Use a towel or rags to prevent scratching the finish. Insert the tip of the drill bit into the tailpipe and drill a 1/4-inch hole in the baffle.
    • 7 Hold the tailpipe up to the light again. Determine the number of additional holes you want based on the purpose of the modification. Drill additional holes in the baffle if needed.
    • 8 Stand the tailpipe on end and tap it on the workbench to clear the debris from drilling out of the baffle. Make sure all debris is cleared out before reinstalling the tailpipe on the motorcycle.
    Slide-In Baffles
    • 9 Secure the outer end of the baffle in a bench vise with the baffle extending to one side. The outer end has the threaded hole where the bolt was removed to take the baffle out of the exhaust pipe.
    • 10 Measure the length of the baffle and divide it by four. You modify a slide-in baffle by cutting off a one-quarter section at a time using a hacksaw. Mark the baffle at the one-quarter point and cut the first section off the end.
    • 11 Reinstall the baffle in the exhaust pipe using the saved bolt and the metric tool.
      Start the motorcycle and determine if the modification produced the desired result.
    • 12 Allow the exhaust pipe to cool completely before removing the baffle for further modification. Most likely, cutting one or two quarter sections will give you the result you want. Avoid cutting too much off the baffle, or it will be useless.

1_16_2013_4_34_52_am.jpg

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1 Answer

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1 Answer

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Good luck

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