How to Remove Baffles From Stock Exhaust
Baffles are installed in stock motorcycle exhaust systems in order to meet regulations regarding emissions and vehicle noise. Removing the baffle, however, remains a popular modification among motorcycle enthusiasts. The baffle acts to muffle the engine, and removing the device will open up the exhaust system, creating a much louder engine sound. Always check your local and state laws before attempting such a modification to avoid serious penalties.
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Things You'll Need
- Grinder
- Drill with 1-inch hole saw attachment
- Flat black spray paint
- Screwdriver
Instructions
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1
Unbolt the entire exhaust system from the engine and chassis of the motorcycle. This will make alterations much easier.
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2
Use a grinder or similar cutting tool to cut the exhaust tip off at the weld joint. Be careful when removing the tip if you wish to reinstall it later, though it is typically discarded and either left off or replaced with a new aftermarket tip. This will open the exhaust pipe and give you access to the front baffle plate.
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3
Use a drill fitted with a 1-inch hole saw to cut holes in the baffle plate around the center pipe. Make sure each hole overlaps the last. Cut holes until the baffle plate is basically removed. There will be some rough edges around the center pipe and the edges of the main pipe.
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4
Use a grinder to trim the edges of the main exhaust pipe smooth. Don't worry about cleaning up around the center pipe, as this will be removed in the next step.
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5
Insert an object such as the end of a screwdriver into the center pipe. The object should be large enough so as to form a snug fit. Forcefully wiggle the screwdriver inside the center pipe until the weld holding the pipe in place breaks. Remove the center pipe and discard it.
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6
Clean up the inside of the pipe with your grinder to remove any remaining rough edges, and apply a coat of flat black spray paint to add a finished look.
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7
Reinstall the exhaust system on the motorcycle.
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Tips & Warnings
If you wish to make a less extreme modification to your exhaust, you can stop short of removing the full baffle plate by only drilling a few evenly spaced holes around the center pipe.
The loud volumes produced by an exhaust system without baffles could cause damage to hearing.
