Kerker Muffler Disassembly

[Mashermoto]

Well this thing is some kinda stubborn

I couldn't stand it no more so I went out and used brute force...the count is muffler 2 and Masher zero

It doesn't want to move either direction. I don't think I'm going to have any success until I get the end cone to come out.

Hmmm...it maybe time to get the metal saws and grinders out Sooner or later it will only be me or the muffler that's left

BTW, thanks for the comments

[Yahman]

Mashermoto,
Yours is exactly like mine and that cone must come out to remove the baffle. Mine is in much better shape and it still took forever to get that cone out the first time. Have you tried heating up the outside of the muffler with a torch? That and pounding on the other end is what finally worked for me.

This is what it looks like disassembled.




If you think a Kerker sounds cool with the baffle, try it without the baffle. Your neighbors will love you for it...

Larry

[Mashermoto]

Yahman,

That's it exactly

I believe I have to give it up to the muffler...It ain't comin out

I've soaked it for two days in PB Blaster, I've heated it, and I've beat on it until the baffle is deformed front and back Nothing worked.

At this point I think the only way to salvage it is to shorten the length by cutting about 3 inches off the outlet side...just behind the cone. Then I could run it without a baffle, or manufacture a baffle.

Oh well...it was cheap and real fun to beat the snot out of it

And BTW, thanks to all of you that took the time to disassemble your mufflers and post pictures. That's awesome support

At least if anyone wants to know what the inside of their Kerker looks like, here is the post to see it I'll post pictures if I do any more work with it. But for now I got an engine to assemble and lots of cool ideas to do. More on that later.

Masher

[DiverRay]

DID YOU DRILL OUT THE OLD BOLT???!!!??? If you left ANY threads from the bolt, the cone WILL NOT MOVE!! I know that from experience with these systems.

[Yahman]

Don't cut it off, try cutting it from a 1/4" in front of the hole straight back to the end. That would relieve the pressure on it.

Larry

[Mashermoto]

No bolt problems...that cone is just in there tighter than Nancy Pelosi's face

Here is what I mean when I said I was going to beat into submission





Trying to force it out by pushing on the cone with the baffle just crumpled the baffle and rounded the inlet. It probably still can be saved if there is a way to get the cone off.

Those guys that used slide hammers might be on to something, but I don't how they did it

[DiverRay]

First, DID YOU DRILL OUT THE OLD BOLT??!! If there are ANY parts of the old bolt sticking up, it will NOT come out! DAMHIKIJK
Second try, heat the outside of the header pipe with a MAPP or Propane torch, and THEN spray just the CONE with PB Blaster. That should enlarge the pipe, and SHRINK the cone just slightly. It should come out after that. You CAN buy new parts for the system, as Supertrapp and Kerker are now the same company.

[Mashermoto]

Diver,

You are correct about the replacement parts. This link has all the Kerker components, but I guy has to know if he has a Kerker KA, KB, KC, EIEIO

http://www.cyclewareables.com/pages/...st_baffles.htm

[oldyam80sg]

About 3 years ago i wanted to try and make a bracket out of aluminum to hold the megaphone to the frame as i didn't like the bracket that came with the system.You have to remove the bolt like Diver Ray said or it wont come apart.The screw(big phillips head)will probably need a shot or two of lube but then it should come out.The best way i found out is to start the bike and let the exhaust get hot,then it should be easier to remove-wear gloves though.I use a pair of welding gloves to handle the exhaust.Without the screw removed you will struggle with it!

[mxmikie]

Well that proves that my Kerker has been thoroughly hacked up. Mine looks nothing like that when disassembled. Mine doesn't even have a cone, just a flat plate with a hole in the center and "custom" drilled holes around the outside. Did they make more that one style? Mine also doesn't have a pipe protruding from the inlet side.

that sounds like a supertrapp baffle

[oldyam80sg]

AAAH the old Supertrapp system-back when you had the discs to add or remove.Have not seen them on many Yamaha's only Suzuki and Kawasaki.

[Mashermoto]

Holy Bat Crap Batman This thing just won't give it up



As you can see from this shot I have removed the bolt. I also lifted the edges up from the cone around the bolt hole. So...that ain't what is holding it



For my next great feat I rented a 5 pound slide hammer from O'Reilly's Auto Parts and went mid-evil on it.



So after breaking out the small ring with the Kerker print on it I set the puller on the inner surface That wouldn't hold up either. I even heated the muffler with a propane tourch.

This means war This muffler may look like hamburger meat after I get done, but I'm getting that cone out Well...it actually looks like hamburger meat now...but you know what I mean

[Mashermoto]

My fellow Americans...I proudly proclaim the war is over...and today is a day that will go down in infamy IT FINALLY CAME OUT...sorry...didn't mean to yell



It took my best head porting tool to grind through the muffler end, but it came out. As you can see there is enough corrosion around the cone that dynamite would not have moved it



It's kinda hard to see but there is a ring of corrosion around the inside as well.



I told you this thing would look like hamburger meat when I got done...and I kept my word



Now comes the fun part...making this thing a true free flowing exhaust and a whole lot of cleaning up First task is throw that small center pipe in the street and straighten out all the destruction I forced on this thing

Stay tuned...more to come.

[BigDick]

As you can see there is enough corrosion around the cone that dynamite would not have moved it

I would have tried the dynamite anyway!

[79XS11F]

I wouldn't alter the Kerker pipes inners. It is all ready one of the most Free flowing pipes you can get. Also keep in mind that a certain amount of baffling is required for the pipe to work properly. The pipe needs to send back pressure pulses to the engine for it to work as intended and as designed. You will likely just end up making it a lot more noisy without any real increase in performance.
Rob.