Yoshimura R-77 Baffle Issue

[CBMGSXR92]

When attempting to take out the baffles on my R-77's, the left side came out no issue, but the right side hex screw looks like its tac welded in place....wtf? Also, based on how many times I've tried to get it out, its petty wallered out now.

My only thought is to drill it and use an EZ-Out, and hopefully that will overcome the weld...? I can't get a Dremel in that small space to cut it out either...

I'm NOT impressed....Lmao

Any suggestions?

 

[Berlin Germany]

cut the welding point with a dremel or so - all with lots of patience.
but don´t drill and use an "EZ-Out"-if the ex-out cracks you´re in biggest trouble.

 

[sixpack577]

Around 2013 Yoshimura started tack welding the baffle bolts.
Supposedly making the baffles 'permanent' so the mufflers could pass decibel ratings.
2013 was also the year you could get a full single R77, or a pair of R77 slipons free when you bought a new Busa.
So the R77's really had to pass sound check then.
Otherwise, they are the same as 08-12 models.

 

[sixpack577]

Worst case, you can drill the rivots out of the muffler sleeve and/or end cap and disassemble it, to gain better access to that bolt.
The mufflers are designed to come apart, so they can be repacked.

 

[voodoodoo]

For next time.. Always use a bit of valve polish paste on the bits before you try to loosen tight screws..

 

[CBMGSXR92]

A guy at Yoshimura got back with me today and confirmed the welds were put in to comply with sound regulations and also suggested I try to get rid of as much of the weld as I can and hopefully the bolt will come out. I'll report back this coming week with the results.

 

[Bumblebee]

A guy at Yoshimura got back with me today and confirmed the welds were put in to comply with sound regulations and also suggested I try to get rid of as much of the weld as I can and hopefully the bolt will come out. I'll report back this coming week with the results.

So pretty much was @sixpack577 told you....it's good to have second opinions.

You can get a variety of tips for Dremels that will make quick work of this.

 

[CBMGSXR92]

Yeah, the kit I bought has a decent beveled grinding stone, but I'll need to get the more precise one for this job based on the small opening.

 

[CBMGSXR92]

Multiple cuss words, one extractor bit and some deep creep later....Lmao

Ended up grinding most of the welds away but still couldn't get anything to turn the bolt, so I just used an extractor and it worked like a charm. She now has the proper deep sound

 

[sixpack577]

It's always something stupid that screws up an otherwise 'easy' job, been there enough times, lol

 

[CBMGSXR92]

Here she is all shined up