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[kev]

Ive got problems with my Vance & Hines 2-1 exhaust
I just got about 4000 miles with it and I think the baffle is rattling. I tried to pull the baffle out and managed to move it about an inch but no more.
My question is how do you get the baffle out, its driving me mad 

Regards Kev

[GregKhougaz]

Hey Kev, 

       When I replaced my cores, I did not know to use lots of WD-40 as a lubricant to remove and reinsert.  When I stuck one, my buddy pulls out his "Muffler Expander," a tool I did not even know existed you can get at most auto part stores.  Maybe that's what you need. 

       Good luck!

[LarryB]

the heat shield needs to be totally removed, there is a set screw holding the flange in place, sounds like you might have a broken set screw. loose enough to rattle, but still hangin on to the baffle. you'll probably have to poke around a bit, get a good source of light, sit on the floor and wiggle the baffle. doesn't hurt to shoot a little PB Blaster in there to help.
keep us up on how it goes. 
by the way, this doss not constitute a MOD, mear repair. when your ready for mods, sound out.

[kev]

Thanks for the advice Guys  
Not sure if there is room to shove that tool up the pipe as there is a plate not far inside (see pic)
lubricant sounds a good idea,
I did check the 2 screws holding the baffle and they were ok, I took them out along with the heat shield last time I tried to get the baffle out.
I will try again with the lub, I just have sort this as it sounds like a bag of nails.

ahh LarryB I see what you mean by mod now, just seemed right to post under exhaust,  but could be useful to someone buying pipes V&H warranty is only 90 days
I am surprised, but not sure if this is typical of after market pipes

[cahdbiker]

Thanks for the advice Guys  
Not sure if there is room to shove that tool up the pipe as there is a plate not far inside (see pic)
lubricant sounds a good idea,
I did check the 2 screws holding the baffle and they were ok, I took them out along with the heat shield last time I tried to get the baffle out.
I will try again with the lub, I just have sort this as it sounds like a bag of nails.

ahh LarryB I see what you mean by mod now, just seemed right to post under exhaust,  but could be useful to someone buying pipes V&H warranty is only 90 days
I am surprised, but not sure if this is typical of after market pipes

Kev, The muffler expander is a great idea, they are available in several different sizes. but if you cannot get one to fit and you think the baffle will slide out with a little coaxing try using a slide hammer with a hook on the end of it so you can grab on to your baffle. I have used this technique before when pulling baffles and it worked fine with no damage to any parts. Good Luck CAHDBIKER

[grc]

kev, this is pretty typical not just of aftermarket pipes but stocker's as well.  Try removing the mufflers and pipes on a two year old Harley and you'll find that those don't just slide right off either.  Usually takes a little persuasion, often accompanied by a little cussin'.  A little penetrating oil, let it sit for a few hours, then try the slide hammer technique.  You might also try heating up the pipe by running the engine for a short time.  The thin metal of the muffler will tend to expand faster than the heavy metal of the baffle, possibly giving you just enough clearance to get the baffle moving.

When installing baffles or mufflers, try a thin film of high temp anti-seize so the next time will go a little easier.

Jerry

[kev]

Thanks for all the tips
I managed to get the baffle out by using plenty of lub and the slide hammer method with a couple of hooks attached
When I took a look at what went wrong with the baffle I found that the cone had become detached from the front end of the muffler and moved to the rear against the baffle plate.  this not only explains the rattle but also the poor performance I had as it really restricted the flow. (pic attached 3 broken welds letting the cone fall to the rear)
Went back in easy with a smear of copper slip.
Thanks again Guys    This web site comes up trumps again.