How to Install Baffles in an Exhaust Pipe

Written by tom glander
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How to Install Baffles in an Exhaust Pipe
Replace the baffle in a muffler when it gets too loud. (Motorcycle exhaust image by Crisps85 from

You know it's time to replace the baffle in your motorcycle's exhaust pipe when the noise becomes a nuisance. In addition to keeping the exhaust sound within a certain decibel range, the baffle's condition may also affect performance. After-market exhaust mufflers are typically where you'd find an exhaust baffle, and maintenance of the exhaust is required at periodic intervals. Manufacturers of exhaust systems for motorcycles usually include instructions on when to replace baffles.

Skill level:

Things you need

  • Socket set
  • Screwdrivers
  • Pliers
  • Wire cutters
  • Drill motor and bits
  • Pop rivet tool
  • Pop rivets

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  1. 1

    Remove the muffler from the exhaust pipe. Unscrew and unbolt all fasteners and remove the muffler by pulling it away from the pipe.

  2. 2

    Disassemble the muffler. Mufflers are held together with pop rivets, so drill out the rivets using a properly sized drill bit. The muffler will come apart in two sections, exposing the inner baffle material.

  3. 3

    Remove the old baffle material. Typically a fibreglass wool, the old baffle may be held in place with light wire. Cut the wire using wire cutters and discard the baffle material.

  4. 4

    Install new baffle material. New fibreglass cotton or other manufacturer-specific baffle material should be applied in reverse of the removal process. If secured with wire, use new wire to hold the baffle in place.

  5. 5

    Reattach the muffler halves. Reattachment is the reverse of the removal process, using new rivets to attach the halves together. Hold the muffler sections together with one hand while using a pop rivet tool to attach new rivets through the existing rivet holes.

  6. 6

    Bolt the muffler back onto the exhaust pipe. Start the engine and enjoy improved sound reduction and performance.

Tips and warnings

  • Wear disposable gloves to protect your hands from fibreglass wool.
  • Do not handle fibreglass wool with bare hands to avoid itching or rash.
  • Protect your eyes with glasses or goggles when drilling and inserting rivets.

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