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Don't ever post on forums but thought this might be useful for anyone looking to remove the baffles from their Vance & Hines Big Radius exhaust.
1) Remove heat shields
2) Remove set screws
3) Spray a little WD-40 into and around end of baffles
4) Stick screwdriver into one of the fins of baffle and tap INTO (towards front of bike) with rubber mallet or hammer....just looking to move baffle forward a little to break loose
5) Find a long, stiff spring (6" works well) and using hook end insert into a fin in the baffle
6) Put your foot onto the peg and pull on spring until end of baffle pulls far enough out to grab with your hands and remove the rest of the way
I tried using pliers which didn't work at all then searched the interwebs for other methods with no luck. Happened to have a spring laying around that ended up working perfectly. This exhaust had around 7k miles on it so they were wedged in there pretty good from the heat and carbon.
'09 Iron 883 with Fuelpak and 4" open, hi-flow round air cleaner....looked up Fuelpak settings for Big Radius and no baffles...input values....bike has never run better. I'll not be putting the baffles back in or any others for that matter.
Hope this saves someone from the aggrivation I went thru trying to get these out.
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V&H Big Radius Baffle Removal...Easy Way
