muffler mods

typed this out for someone thought i would post it here.

muffler/pipe baffle mods

In this how article I will show you how to remove baffles, mod mufflers, or slip on exhaust systems. First there are many different motorcycle exhausts systems to be aware of. There are different pipes for optimum performance for there specific motorcycles. But mainly we will be focusing on sport bike exhausts, now days the systems have increased hp then ever before, and adding a after market system increases hp far more. Better motorcycle exhausts remain in there heat absorption and lightness and the right amount of pressure produced , for better performance and reliability.


Okay before you do anything, lets talk about the motorcycle exhaust that is currently on your bike, is it a under tail system? Or in a regular position (on the side) ? It really does not matter, so don't worry,just as long as it can be removed. so how do we mod these pipes. There are many stock systems that have rivets, these rivets are permanently holding the pipe together, some have bolts, that can can be taken off to expose the inner core of the pipe or baffle easily. Most of us are aware of how to unscrew a bolt? So lets talk about the rivets, the only way to disassemble a pipe with rivets is to drill them out, in which the rivets are no longer holding the piece back together, when doing this, make sure all rivets still have some attainability, by only drilling enough so that they can still be used, but at the same time, drilled enough so it can be pulled apart, however you may need to purchase some . Once this step is reached you can start to disassemble! Remember to keep your parts in order! Now that we have our pipe in pieces, lets get to the baffle.


Okay now we can get started! The baffle is made of small fiberglass pieces! So its highly recommended that gloves are used. Use your judgment on how much you want to take out, it works like this, the more fiber glass packing taken out, will reduce the amount of back pressure, be aware of how much you take out, try about three to four thin top layers, for a good amount of back pressure, it may, and most likely differ but 3 to four is about a quarter of the packing. if you are looking to have racing type exhaust most baffle to all should be removed this will be extremely loud, and would have decreased any or all pressure given off. This is popular in most GP racing bikes, but not practical and should not be used on puplic roads. But to increase hp the core baffle cylinder can be opened up as well, giving it a louder, deeper tone which is common. Now that you have decided what fits your needs in baffle adjustments try a test run by starting your bike up with the pipe placed over your expansion chambers or ( mid pipe ) if the pipe is to loud, add some more fiber glass packing in again until it fits your needs.

Now we put are pipe back on! if you have used rivets to do this, put your knew ones in, or add the originals back on and bend the tapered ends back in/out to secure the pipe together, your bike should now feel a little better and sound nicer as well if you do not like the results, try adding more are less packing in until you are satisfied.

Well done Alex! Just gotta add you may need to get a rivet gun cause I've never seen anyone able to reuse a drilled out rivet!

i have heard one guy with a older hurricane reuse his rivets on a muzzy pipe...i would buy them just to be safe...and smart

Reusing old rivets? why? they are dirt cheap.
although if you are pulling it apart often screws might be nicer, just remember to use locktight so they don't rattle loose

Man bottlecape you bring up a good point that I didn't think of. Anything besides rivets (or MAYBE really tightly glued bolts) would definitely rattle out. I've had a lot of my bodywork bolts and even one on the gas cap vibrate out since I finished my bike build!