How to modify suzuki motorcycle baffles

Written by william machin
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How to modify suzuki motorcycle baffles
Suzuki motorcycles have exhaust baffles inside the tailpipe. (Jupiterimages/ Images)

Motorcycle exhaust baffles limit noise emission and create backpressure in the exhaust system. Modifying the baffles on your Suzuki motorcycle is relatively uncomplicated, but you have to consider a couple of things. Newer sport bikes like the GSX-R750 and GSX-R1000 have tuned exhaust systems with specially designed baffles. Modifying these can alter the tuning and affect engine performance. In addition, newer Suzuki baffles are incorporated into the tailpipe construction, unlike older types that simply slide in. You can modify Suzuki motorcycle baffles in a workshop using hand tools and light power tools.

Skill level:

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Things you need

  • Suzuki service manual (year and model of your motorcycle)
  • Metric tools
  • Electric drill
  • 1/4-inch drill bit
  • Drill bit extension (Optional)
  • Bench vice
  • Hacksaw
  • Flat file

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    Take Down

  1. 1

    Park the motorcycle on the kickstand or centre stand and allow the exhaust pipes to cool completely.

  2. 2

    Refer to your Suzuki service manual and organise the metric tools needed to remove the baffle. On newer models, it may be necessary to remove the tailpipe section to modify the baffle. On older models, you may be directed to remove a bolt that secures the baffle in the tailpipe.

  3. 3

    Follow the procedure given in the manual and remove the tailpipe section or slide-in baffle using the appropriate tools. Save any brackets or bolts. Place the tailpipe or baffle on a workbench.

    Tailpipe Baffles

  1. 1

    Hold one end the tailpipe up to a light and look inside the other end. Depending on the baffle, you may see very little light or none at all. Modifying the baffle is a matter of opening up areas in the baffle.

  2. 2

    Chuck a 1/4-inch drill bit in an electric drill. Use a bit extension if necessary to reach deep into the tailpipe with the drill bit.

  3. 3

    Place the tailpipe on a workbench. Use a towel or rags to prevent scratching the finish. Insert the tip of the drill bit into the tailpipe and drill a 1/4-inch hole in the baffle.

  4. 4

    Hold the tailpipe up to the light again. Determine the number of additional holes you want based on the purpose of the modification. Drill additional holes in the baffle if needed.

  5. 5

    Stand the tailpipe on end and tap it on the workbench to clear the debris from drilling out of the baffle. Make sure all debris is cleared out before reinstalling the tailpipe on the motorcycle.

    Slide-In Baffles

  1. 1

    Secure the outer end of the baffle in a bench vice with the baffle extending to one side. The outer end has the threaded hole where the bolt was removed to take the baffle out of the exhaust pipe.

  2. 2

    Measure the length of the baffle and divide it by four. You modify a slide-in baffle by cutting off a one-quarter section at a time using a hacksaw. Mark the baffle at the one-quarter point and cut the first section off the end.

  3. 3

    Reinstall the baffle in the exhaust pipe using the saved bolt and the metric tool.

    Start the motorcycle and determine if the modification produced the desired result.

  4. 4

    Allow the exhaust pipe to cool completely before removing the baffle for further modification. Most likely, cutting one or two quarter sections will give you the result you want. Avoid cutting too much off the baffle, or it will be useless.

Tips and warnings

  • Do not cut the solid end of a drilled baffle. Drill additional holes to make modifications.

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