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2002 XR250r Baffle Removal

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Posted by: APFornadel---------------------

What is the best way to remove the baffle from my exhaust pipe on my XR250? I unscrewed it and it seems as though they welded it in at the factory. I have read numerous threads that say, "Remove the Baffle, replace with ...", but not a single one says how to go about removing it. I appreciate any help. Thanks in advance.



Posted by: morbidsmurf---------------------

on my '00 xr250r i took off the whole end cap and put on a baja designs one. i will put a contact on here as soon as i find it



Posted by: Mike R.---------------------

Take out the whole thing (3 screws).
Now remove the Torx bit on bottom holding in Small diameter baffle.
take 2 screw drivers and carefully work it back and forth around underedge of black nozzle area.
See, the problem is those are not to tight when new but after a year or so the build up of carbon and etc casue it to stick tight inside the outter piece.
Take a look at where you remove that Torx bit you can tell it slips down inside there.
I was able to get mine out in about 10 minutes of wiggling.
If you still dont understand post e-mail me at panzersox@woh.rr.com and I will get you pics with more concise and clear instructions.




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