How to remove exhaust baffles

Written by kevin krause
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Exhaust baffles are special sections located in the tailpipe of most motorcycles that aid in reducing the sound produced by the motorcycle engine. The baffle consists of a chambered section filled with fibreglass, and to remove the baffling effect you only need to cut or open up the baffle chamber plates to allow exhaust to bypass the baffling system. The modification is fairly common and can be accomplished in only a few hours with the proper tools.

Skill level:
Moderately Easy

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Things you need

  • Ratchet
  • Drill
  • 1-inch hole saw
  • Grinder
  • Dremel tool
  • Hammer and chisel
  • 1/2-inch dowel rod

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  1. 1

    Remove the entire exhaust system from the motorcycle to allow for easier modification to your exhaust baffles. Unbolt the exhaust from its attachment points to the cycle chassis and the motor.

  2. 2

    Cut off the tailpipe cone from the main exhaust pipe using a Dremel tool. The cone will not be reattached and can be discarded. A new exhaust tip can be installed later or the pipe can be left without a cone. Sand down the edges of the exhaust pipe for a smooth finish if this is the case.

  3. 3

    Use a 1-inch hole saw attached to a drill to cut holes in the exposed front baffle plate around the centre pipe. Start by drilling four holes, one located each at the 12, 3, 6, and 9 o'clock positions. This will open up the baffle and create a louder exhaust sound. This modification will be suitable If you only want a mild sound increase. If this is the case, reinstall the exhaust system to your bike. If you would like a louder exhaust, drill more holes or move on to Step 4.

  4. 4

    Drill several more holes in the front baffle, each hole overlapping the last. This will effectively remove the entire baffle plate, though there will be some rough edges.

  5. 5

    Knock the jagged edges remaining from the baffle flat with a hammer and chisel.

  6. 6

    Insert a thick dowel rod, 1/2 inch in diameter or larger, into your centre pipe. The rod should fit snugly. Twist and wiggle the rod with some force until the centre pipe breaks free of its weld and separates easily from the exhaust system.

  7. 7

    Clean the inside of the newly opened exhaust pipe by knocking any remaining rough edges flat with a chisel or using a grinder. Reinstall the exhaust system.

Tips and warnings

  • Apply a coat of flat black spray paint to the inside of the pipe for a nice, finished look.
  • Motorcycles come stock with exhaust baffles to meet the noise and emissions standards set up by local and state governments. Any modifications should be completed taking local laws into account.

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