Removing RD muffler

[VonYinzer]

Spanner wrench.

 

[2_DONE_THE_TON]

grrrr...so heres the story:

today i heated the muffler witht the torch (see the color of the end) and tried to pull it out with a slide hammer....it didnt move..seems like the pre.owner never ever removed them....
then i (stupidly) tried to hammer it a little bit further in...to loosen the grime all around the fitting..it moved in 2MM...again no possibility to pull it out with the slide hammer.
i´m PISSED.
so im now trying to soak it overnight in petroleum and give it another go.

what you guys think?any ideas how to get that stuck up sucker out<?

 

[Tim]

Uh - is that supposed to come out? I'd tend to think if you could pull it out, it would fall out when you were riding.

 

[AlphaDogChoppers]

You noobs just don't listen, do ya...

Oven cleaner! It'll dissolve the carbon and oil, and that thing will come out slicker than a cat's ass.

 

[2_DONE_THE_TON]

You noobs just don't listen, do ya...

Oven cleaner! It'll dissolve the carbon and oil, and that thing will come out slicker than a cat's ass.

haha alpha i tried oven cleaner....i will only dissolve the goo on the surface of the baffle...i think the problem is that the "inner" and the other circular metal surfaces (the surface on which the muffler should slide out.)
when i tried to move it some kind of carbonized stuff came out..either the surfaces "melted" together trough rust or im just stupid.

 

[xb33bsa]

soaking it may help i hope so !
also if you can grip the pin and try twisting ,cut a slot in a pipe to use as a tool..
after soaking as you are doing try heat again and re-soaking if needed
good luck

 

[2_DONE_THE_TON]

soaking it may help i hope so !
also if you can grip the pin and try twisting ,cut a slot in a pipe to use as a tool..
after soaking as you are doing try heat again and re-soaking if needed
good luck

ill try to heat it after the soaking on petroleum (after is washed it off with water,or it prob blow off in front of me)...and if it doesnt work ill soak it in oven cleaner...

 

[VonYinzer]

Take the head pipe off. Will allow you to get at both sides of the baffle.

 

[VonYinzer]

Uh - is that supposed to come out? I'd tend to think if you could pull it out, it would fall out when you were riding.

It does. The smokers build up a shit ton of carbon and unburnt goop. Supposed to be cleaned regularly.

 

[Tim]

Ah - coolio. No mechanical fasteners? Just a press fit?

 

[AlphaDogChoppers]

Ah - coolio. No mechanical fasteners? Just a press fit?

If you go back through the thread, you'll see a picture of the screw that holds it in.

 

[AlphaDogChoppers]

haha alpha i tried oven cleaner

Try it some more. Really saturate the baffle. You want to get the oven cleaner into all the spaces between the baffle and the muffler.

Grab that cross bar with a Vice Grip. Twist back and forth and pull. You will have to be persistent. If you can get it to wiggle at all, you will make progress. Twist-pull-twist-push-twist-pull shoot some more oven cleaner in there twist-pull. You will wear down its resistance.

 

[2_DONE_THE_TON]

Try it some more. Really saturate the baffle. You want to get the oven cleaner into all the spaces between the baffle and the muffler.

Grab that cross bar with a Vice Grip. Twist back and forth and pull. You will have to be persistent. If you can get it to wiggle at all, you will make progress. Twist-pull-twist-push-twist-pull shoot some more oven cleaner in there twist-pull. You will wear down its resistance.

last time i just sprayed it next time ill buy a galllon and soak that sucker up.ill let you know if i succeeded.

 

[crazypj]

Remove the screws, pull out the baffles, clean them, put them back in. It's part of basic preventative maintenance with a 2T bike. There is no packing in a RD250 muffler. Please pick up a service manual for the bike, it's all in there

Yes there is or at least should be.
We were told to remove it at first service because it blocked up so easy and destroyed performance (except it didn't, packing double the amount 'converted' it into a 'stinger' 8) )
It's only about 1/4" thick on the last 4"~5" before the end piece where screw fits (the ~5/8"dia perforated tube section)
The best way to pull them is with a special slide hammer, needs to have a 'flat' hook that fits almost full width of the cross bar.
It was rare in most shops even when they were selling two stroke bikes
It may also help if exhaust is HOT (hot enough for severe burns)

 

[2_DONE_THE_TON]

SUCCESS!!

today i removed the downtube...with my daddys spanner wrench.
after that i used a metalbroomstick to punch that sucker out with a hammer...

there is packing...altough pretty much run down...im now cleaning everything inside..cleaning the baffle and thinking about the packing....what kind of packing material should i use?should i pack more or less than original?
i think after those 30.000 km without removing the baffle...i suppose it never came out...using a slide hammer (which i tried) is obsolete.

We were told to remove it at first service because it blocked up so easy and destroyed performance (except it didn't, packing double the amount 'converted' it into a 'stinger' 8) )

ill definitely gonna pack it...its really loud already

 

[teazer]

That looks like a lot of oil there. Clean out the muffler first with kerosene or similar or burn it out, but don't use kerosene and then set light to it !

Remove the packing from the baffle tube and clean it thoroughly with a wire brush and you will probably want to burn off the oil and carbon OUTSIDE the shop, not inside. Buy two stroke muffler packing. You want the stuff that is white and comes as a thick blanket, not the loose pink stuff. Lightly wrap a piece around the rear section and hold it in place with thin lock wire.

Do not over pack it. I tried a few times to squeeze in more packing and the noise went up, not down - sa PJ mentioned.

 

[2_DONE_THE_TON]

That looks like a lot of oil there. Clean out the muffler first with kerosene or similar or burn it out, but don't use kerosene and then set light to it !

Remove the packing from the baffle tube and clean it thoroughly with a wire brush and you will probably want to burn off the oil and carbon OUTSIDE the shop, not inside. Buy two stroke muffler packing. You want the stuff that is white and comes as a thick blanket, not the loose pink stuff. Lightly wrap a piece around the rear section and hold it in place with thin lock wire.

Do not over pack it. I tried a few times to squeeze in more packing and the noise went up, not down - sa PJ mentioned.

thanks pj!

i bought a mat of baffler material plus a stainless steel lock wire today.how thick do you pack your rd´s muffler?stock is maximum 2 layers of wrapping.
how do you wrap the wire?do you criss cross or is there a special style of wrapping it?

 

[crazypj]

Can't remember how much wire you need but start with about 2~3 ft, use 'middle' of wire; wrap a loop one end then spiral to the other end and twist wire ends after you make another loop
You can also just spiral wind.
Overpacking can increase top end performance but it will have a real loud 'crack', not too bad if racing 'Production class' but probably not a good idea on the street