Removing D&D baffles

[HellFire]

I've been looking into ways to get the baffles out of my D&D's for some time. My biggest fear was damaging the chrome and the baffles themselvs. I didn't want to tear up the baffles so badly that I would not be able to put them back in down the road. I found a puller set up that works. Harbor Freight has a "blind hole puller" that is $40 and works. The whole operation took about 45min and I've already put one back in just to control the noise a little better.
So, if anyone is interested in the details just ask. I'll post the whole operation if someone needs the help, otherwise I'll leave it like this ... It can be done without damage.

Oh, and it works wonders getting rid of that annoying triple filter intake noise!

 

[JRock]

I've got the D&D's and I would appreciate the writeup, with pics if you can. Thanks.

 

[HellFire]

Lemme see what I can do about some pictures of what the baffles look like out, I know that would have helped me out just knowing what was in there to deal with.I'll get back with ya.

 

[HellFire]

Jrock I havn't forgotten you, I'm having trouble with my **** camera. I had every intention of getting something usefull up here this weekend but murphy reared his ugly head. Soon ... I hope.

 

[JRock]

It's cool. Not in a hurry to tear apart my pipes. thanks

 

[HellFire]

D&D Baffle Removal

Ok, got the pictures. The puller is from harbor freight, it's called a "blind hole bearing puller" and cost $40. I used the largest of the puller ends and lubed the inside expander well so that it could be adjusted easily while inserted into the baffle. There is no way to get a wrench on it once it's in the exhaust. 1st remove the bolts that hold the baffle in the pipe. Expand the puller so that it will just fit into the baffle and expand it further once inserted by applying pressure sideways while turning the tool clockwise. You will need to insert it far enough in to get at the stamped baffle vents that line the smaller inner pipe. Getting it to bite the vents while trying to expand the end inside the baffle is the hardest part but patience will prevail. Lightly tap the slide hammer over and over, it will not come out with one pull. Most likely the puller will slip out several times during the process so you will have to readjust the end, reinsert it and snug it up again. Keep tapping ... it will only move small amounts each time so I just kept at it while turning the tool clockwise to continue tightening its hold. Again, be patient and tap lightly, I don't think you can break the mounts but why risk it. I've included pictures of the tool and what the baffles look like removed. Knowing what the baffles look like will help you know what you're up against. (note: pipes must be mounted and secured on the bike to use this method)

 

[JRock]

Good stuff. Thanks alot.

 

[Btubbs2]

this is awesome and thank you. i tried removing and pulling this morn without all the info, but this totally makes sense. can't wait to try it!