How to Remove Baffles on Vehicles

by Contributing Writer; Updated June 12, 2017

Vehicles are a type of motorcycle exhaust system that can provide more sound and power from your motorcycle. However, if you are after even more hearty, throaty roar from your bike, plus a decent horsepower boost, you can remove the baffles from the Vehicles. The baffles are the metal inserts located inside the Vehicles exhaust Vehicles that act as a disruptor to tone down exhaust flow and noise. Removing the baffles essentially turns your exhaust into a straight Vehicles configuration with no muffling abilities whatsoever. If this is the sound you are looking Vehicles then you can quickly and easily achieve it by following this step by step process.

Under The Hood:

 How to Remove Baffles on a Motorcycle Exhaust

Use your owner's manual to determine exactly how the exhaust is connected to your motorcycle model. Unfortunately every bike is different, but most will be held on by two bolts at the cylinder head and two at the rear of the bike.

Set the motorcycle on its kickstand or centerstand so it will not tip or fall while you are working. If you have a dedicated motorcycle work-stand, that will provide a much easier means of removing the exhaust.

Use a socket wrench and the appropriate size sockets to remove the exhaust completely from the motorcycle. Cover any open holes in the cylinder-head of the engine to keep it free of moisture and debris while you are working.

Clamp the exhaust system in a vice. Cover it first in shop rags to save any chrome from being damaged or scratched by the metal surface.

Insert the end of your hand held drill with a 1/2" or 3/8" metal cutting bit into the end of the muffler. Drill through the first and second exhaust baffles carefully. Most motorcycle exhaust systems have three or four baffles. Drilling through all of them will require re-jetting the carburetors due to lack of compression.

Remove the exhaust system from the vice and reattach it to your motorcycle using the hardware you removed earlier. Refer to your owner's manual for torque specifications and be sure all bolts are tight. Crank your bike and listen to the new, deep and loud exhaust tone.

Items you will need

  • Basic wrench set

  • Metal cutting drill bit

  • Hand held drill

  • Vice

  • Shop rags

 How to Remove Baffles From a V-Star

Position yourself at the end of the V-Star's exhaust. Insert the 1-inch hole saw into the drill. Insert the hole saw into the end cone on the exhaust, which is the exhaust tip, and drill out the end cone with the hole saw. Shine the flashlight inside the exhaust and find the first baffle plate, which is held in place by circular spot welds. Drill out those spot welds with the metal drill bits and the drill.

Remove the remainder of the first baffle with the chisel and the hammer. Remove the second baffle inside the exhaust with the 24-inch chisel, as well as the two small exhaust pipes located inside the overall exhaust assembly.

Shine the flashlight down the exhaust pipe assembly and locate the third baffle plate. Remove the third baffle inside the exhaust with the 24-inch chisel. Now all of the optional baffles are removed.

Items you will need

  • Flashlight

  • Hammer

  • Drill

  • Metal drill bits

  • 1-inch hole saw

  • Chisel

  • 24-inch long chisel

 How to Remove the Baffles From a Softail Exhaust

Use your owner's manual to locate the bolts that mount the exhaust to the frame and cylinder head of the motorcycle. Every bike is different in this regard.

Set your motorcycle on its kickstand so it will not fall over while you are working on it.

Remove the exhaust system from the motorcycle by removing the exhaust mounting bolts with a combination or socket wrench.

Cover your vise or metalwork stand with shop rags, paper towels or another soft material to keep the chrome surface of the exhaust safe from scratches and dents. Clamp the exhaust in the vise or stand.

Install a metal-cutting drill bit 3/8 or 1/2 inch in size onto your hand-held drill. Drill through the first baffle on the inside of the muffler then the second. Do not drill through all of the exhaust baffles or the compression of the engine will suffer, requiring a carburetor rejet.

Remove any metal shavings or pieces from the end of the muffler. Use a combination or socket wrench to reattach the exhaust to the motorcycle frame and cylinder head. Be sure all bolts are tightened to the torque specifications found in your owner's manual, then start up the bike and listen to your new, low and loud exhaust.

Items you will need

  • Basic socket set

  • Metal-cutting drill bit

  • Hand-held drill

  • Vise or metalwork stand

 How to Remove Baffles From Harley-Davidson Pipes

Remove the bit from your drill, and attach the hole saw. While a battery-operated drill will suffice for this job, you may wish to use an electric drill.

Coat the end of both exhaust pipes with cutting oil or WD-40, taking care to coat the pipe fully where the baffles are. You should keep the pipe fully coated with oil during the cutting process to keep the drill and saw blade from overheating and to reduce the risk of accident or injury.

Cut through the rear of the upper exhaust pipe, just above the chrome ring. Continue cutting until you have penetrated the first and second layers of the pipe.

Clamp the vice grips onto the baffle, and twist the baffle to remove it from the interior of the exhaust pipe. The baffle is a metal piece inside the pipe that muffles the sound of your Harley's engine exhaust.

Remove the baffle from the lower pipe by repeating the process. You may need an arbor extension for your hole saw to reach the inside of the lower pipe. You may also choose to loosen the pipe from your Harley while you remove the baffle to avoid using an arbor extension for your saw.

Items you will need

  • Electric drill

  • Vise grips

  • WD-40 or cutting oil

  • 1 3/4-inch bi-metal hole saw

  • Saw arbor

  • Arbor extension

 How to Remove the Baffles From a Harley Exhaust

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, taking care 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.

Items you will need

  • Electric drill

  • Vise grips

  • 1 3/4-inch bi-metal hole saw

  • WD-40 or cutting oil

 How to Remove Baffles From Cobra Pipes

Locate the baffle screws on the back, middle portion of the Cobra tailpipes. Use the screwdriver to loosen and remove the baffle mounting screws.

Slide the baffles out of each one of the tail pipes.

Replace the baffle screws in the pipe itself to prevent corrosion from water trapped inside the pipe. Start the bike up and listen to your newly modified motorcycle exhaust.

Items you will need

  • Screwdriver

About the Author

This article was written by the It Still Runs team, copy edited and fact checked through a multi-point auditing system, in efforts to ensure our readers only receive the best information. To submit your questions or ideas, or to simply learn more about It Still Runs, contact us.