How to Remove the Baffles From a Vulcan 900 Custom

Updated April 17, 2017

If you are looking for a way to add more sound to your Vulcan 900 Custom motorcycle, an easy way to do it is to remove the baffles. The baffles are located in the pipes of the exhaust system of your Vulcan and can be removed without damaging the bike. You can take your bike to a motorcycle mechanic to have this done, but the cost will be much higher than doing it yourself using tools that you probably already have on hand.

Remove the bit from your drill and attach the hole saw. An electric drill works well for this purpose.

Coat the exhaust pipes with WD-40 or cutting oil, being particularly careful to coat the pipe fully where the baffles are. Keep the pipes coated with oil while cutting to reduce the risk of accidents and to keep the drill and saw blade from overheating.

Cut just above the chrome ring on the end of the exhaust pipes one at a time. Continue cutting until you have gone through the first and second layers of the pipe.

Clamp the vice grips onto the baffles and twist the baffles one at a time to remove them from the inside of your exhaust pipes. The baffle is the metal piece inside the pipes.

Put the exhaust pipes back on the bike if you removed them for the drilling process.


You may wish to remove both exhaust pipes from your Vulcan before removing the baffles to make the job easier.


Keep the exhaust pipes covered with oil while cutting them to reduce the possibility of accident or injury.

Things You'll Need

  • Electric drill
  • Vice grips
  • 1 3/4-inch bimetal hole saw
  • WD-40 or cutting oil
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