well I started the exhaust mod posted on the web site. started out no problem, I took 1/8 inch punch and got all the rivets punched through. I then took my trusty vice grips. fastened them perpendicular hit with hammer and got the first baffle out no problem.
The other 3, not so much luck. All the rivets are pushed through but i cant get the baffles to budge. the stock exhaust tips are actually starting to tear where the vice is clamped. I stopped the project for fear of damaging them further and ripping them to the point i could never get them out.
any advice or techniques for removing them out there that i am unaware of?
Also on a side note, since my stock exhaust tips are so damaged (or will be when this is done) I was planning on leaving them off (as oppesed to putting them back on with new rivets after cutting away the baffle). Any word on if i will need to rejet? Also I think my bike may be a cali bike so i think it may have small jets to begin with?
Did you drill the rivets before you punched them out? Sometimes when you use a punch it flares the holes together. you may also have a little carbon build up on the resonator where it goes thru the last baffle, try working the end plate back and forth by sticking something in the hole like a 1/2 inch drive extention and moving it side to side. Hope this helps, maybe someone else will have another trick or two.. If you tear up the end plates let me know I may have a set I can trade you..
When I bought my 2000, the PO had removed the baffles. It was painfully loud. I think you will want to replace the end plates.
I used a center punch or something like it to work the rivet loose. If the pipe is damaged you can use some copper plumbing pipe to replace it, they have a size just smaller than the original that you can tap in and cut to fit the shape of the original.
Bob
I'll second Mr. Otwell on this one. I punched out the first set of rivets, took me over a half hour to get the whole thing loose. The other three I took a drill to. Took about 12 seconds per pipe to get all the rivets out. I just drilled in and then moved the drill bit around the hole to clear out the rest of the rivet.
A drill is faster, however must be very careful not to "waller" out the tabs or on the back top side drill though the outer shell of the muffler.
I have used a drill in the same size as the rivets to get through the majority of the rivet, then take the punch or awl and waller it a bit and voila she comes out.
I did the mod as specified on the web site as well.
I know exactly what you are talking about with the piping seperating. All four of mine did that but it wasn't until I was done that I noticed it. I just took some duck-bill pliars and "tweaked" them to flush again.
However, if you look really closely those are just lightly tacked. It isn't a solid tube. It looks like it was flat and rolled to fit. I don't think I could have made that straight of a tear in the metal at the same location on all four pipes if it wasn't just tacked.
Definitely use the awl (or punch) like the directions say because using the drill on the first one the hole was just a touch too big. Luckily I have access to some bigger rivets or I'd be hating life.
Hope it helps you out.
Brandon
USAF