how to remove end caps on 2006 s2r 800

[madderdaddy]

Hello there. Im doing a core job on my stock s2r cans. Following all the instructions I have found on the internet I have successfully cored the cans and now im trying to get the section inside the endcaps out so I have the full exhaust hole instead of having the large diameter endcap with a smaller diameter exhaust hole inside the larger diameter hole. Ive been at it for a while now and cant seem to get it out. If you can understand what im trying to get to please help me out. Also if you have any pictures to help me that would be great.
Thanks

[teddy037.2]

we followed one of the write-ups closely when we did DRKWNG's S2R cans...

IIRC the only tools we really used were a dremel and a hacksaw.


we may have had a hammer, too

[madderdaddy]

Yes, but how did you actually remove the inside of the endcap. ive dremeled, hack sawed, and pulled with plyers... still no budge.

[booger]

I don't get how you successfully cored the cans if you haven't yet removed the baffles. That's the first step to getting the endcap off and further disassembly. Baffling.
The usual method is a Dremel tool with a skinny flex head attachment and a metal cutting wheel.

[madderdaddy]

Endcaps have been cut off with a horizontal band saw. Baffles were removed. On the endcaps there is a pipe inside the endcap that was attached to the baffle. I would like to remove that so the endcap is just one big exhaust exit. no little exhaust exit in the large diameter endcap. My terminology may not be correct. If you can understand what I'm saying please help.
Thanks

[TobyDanger]

I haven't done this myself but my understanding is that they are more or less just press fit (fitted?) into the exhaust port.  A slide hammer is one method to try and remove them.  I've also read of inserting a slightly smaller diameter pipe or pry bar and levering back and forth to loosen it up.  You could also try to dremel a cut or cuts on the inner diameter to weaken the metal so that twisting or prying or hammering is more effective against the inner port metal.

Good luck!

[brimo]

theres a couple of little welds inside that you'll need to cut with a dremel.
They are where the tubular shaped part goes through the circular pressing.
If you've successfully cut those, it should Knock out from the inside using a slide hammer.
I've just checked mine and there isn't any weld around the outside of that circular piece.

[DucLeone]

locate the two welds inside the small pipe use a dremel to cut them out


with a little force pull out the section you just cut off


at this point you will see the two brackets that hold the can and the endcap together
separate at the weld and cap will come right off


cap off


slide aluminium can off the actual can ( so you dont end up destroying it )


cut the end of the can along the pipe and along the inner side of the can
(pipe is still long on the inside)


now cut the pipe (i did through the inside with a dremel cut off wheel )
 

slide alu can back over the whole thing insert end cap make sure its sitting tight
drill some holes and i used selftapping screws (rivet are an option)
install back on bike and give it a wrrroooammmm!!!!!!

[madderdaddy]

Thanks slot, this helped out allot. After hours of beating i was able to force it out. I understood how the tabs(brackets) were attached after getting the 1st one done. Now with your method and my knowledge of how the endcap is held to gether i will be able to do it much easier with the second one.
Thanks to all [moto]

[yotogi]

The instructions in most of the how-tos are slightly off for the cans that I started coring. You have to dremmel the welds holding the part inside the exhaust exit, pull that out, then dremmel out the interior welds before you can pull the endcap. Sounds like you figured that out after the first one.

GL on the rest of the mod!