Suzuki 2 Strokes

One of the lower baffles on my exhaust is completely stuck in its mounting hole. The bolt came out just fine but we can't get the baffle out. We repacked the other 3 baffles and it has made the bike sound just that much better so I really want to repack this last one.

Any suggestions on how to get it out without ruining anything?

In my limited experience, it's better to get teh baffles to rotate and then "screw them out" in other words keep rotating them as you pull them out.

To get them started you could grab a cheap socket that would fit inside the end of the baffle, and cut a slot in the hex end to fit around the "cross bar". Use a little force and a lot of WD40 and see if you can persuade it to move. Once it rotates, use a pair of pliers or vice grips to grab teh bar and twist it out slowly.

I have seen people recommend teh sue of a slide hammer of some sort to hammer it out, but I'd rather find a way to screw it out rather than screwing it up.

I would do that but the problem is that the bottom baffles (center cylinder) don't have that crossbar so I can't rotate it.

I just had this problem with the two centre pipe baffles on my Buffalo. We fashioned a tool that had a small hook on one end (to attach to the baffle remanants) plus a sliding handle that we could use to bash against the opposing end (hand held part). A hollow, rounded piece of wood slid up and down the long handle to do the bashing. This got the two VERY stuck broken baffles out in short work without any damage.

We are now going to advertise it on ebay as a very rare, factory tool for the GT series

you can buy a cheap slide hammer for less than 10 bucks.

Hmmm ... looks prettier (and a tad more professional) than our one But that is essentially what we used.

MikeH1A wrote:Hmmm ... looks prettier (and a tad more professional) than our one But that is essentially what we used.

Sorry to burst your bubble Mike. I thought a while back that I had invented the internet. Then I find out that Al Gore beat me to it. Missed it by that much.

Remove the muffler and heat the baffle as hot as you can get it, and as far in as you can with a torch. Keep the flame on the baffle, not the chrome! When it is hot (the hotter the better) quench the baffle end of the pipe in a bucket of cold water. Just be careful of the steam that's going to come out of the other end! Wear gloves and glasses!
The sudden cooling should loosen up the baffle.