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How to remove Suzuki intruder baffles

Removing exhaust baffles from your Suzuki Intruder or Marauder not only produces a loud throaty exhaust note, it also boosts engine horsepower to a certain extent by reducing exhaust backpressure. However, the subsequent increase in air flow through the through the carburettor induces a lean fuel/air mixture during idling, therefore the carburettor idling mixture screw requires adjustment. Stripping baffles from your exhaust pipe/s is a fairly strenuous, time-consuming project that calls for basic do-it-yourself expertise.

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  1. Locate the three rivets securing the chromed baffle cover to the end of your exhaust pipe. Pop-mark the highest point on the rivets with a centre punch and hammer. Drill through the rivet heads with a 6 mm twist drill and cordless drill, and remove the baffle cover disc to reveal the rearmost baffle plate.

  2. Clamp a 52 mm carbide tipped hole saw into a two-speed electric drill and set the drill to its lower speed. Insert the hole saw into the exhaust pipe and lubricate the cutting edges with a liberal amount of light household oil. Turn the drill on and cut through the first baffle disc; this will take 15 to 20 minutes. Allow the holes saw to do its work without applying excessive pressure to the drill handle, and keep lubricating the cutting edge as you work.

  3. Repeat by drilling out the second and third discs. The last disc is made out of hard high-tensile steel, so drilling through the third disc takes a little longer. The pipe protruding from the baffle assembly will be visible once you cut through the third disc.

  4. Insert the end of a pair of long-nosed vice grip pliers into the exhaust pipe and clamp the jaws on the end of the pipe protruding from the baffle assembly. Twist the pliers back and forth to loosen the assembly and slide it out of the exhaust pipe.

  5. Repeat the above procedures with the second exhaust pipe to complete the project.

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Things You'll Need

  • Centre punch
  • Hammer
  • 6 mm twist drill
  • Cordless drill
  • 52 mm carbide tipped hole saw
  • Two-speed electric drill
  • Light household oil
  • Long-nosed vice grip pliers

About the Author

After graduating from the University of the Witwatersrand and qualifying as an aircraft engineer, Ian Kelly joined a Kitchen remodeling company and qualified as a Certified Kitchen Designer (CKD). Kelly then established an organization specializing in home improvement, including repair and maintenance of household appliances, garden equipment and lawn mowers.

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