Complete De-baffling of VN 900 Exhaust

[84_KZ550_NewB]

Ok from what I read, when people debaffle an exhaust you have to rejet or make adjustments? Is that true? Cause I have a KZ550 and would like to debaffle but I really don't want to rejet/adjust or anything...

Nice bike BTW!

[07custom36]

If i want to just to take the baffles out all together how long do you think it will take me to do?

[predfan2001]

Originally Posted by 84_KZ550_NewB

Ok from what I read, when people debaffle an exhaust you have to rejet or make adjustments? Is that true? Cause I have a KZ550 and would like to debaffle but I really don't want to rejet/adjust or anything...

Nice bike BTW!

The 900 is EFI so debaffling is ok. I've heard that if you modify the exhaust and intake, you need a power commander (??? I think thats what they're called).

Originally Posted by 07custom36

If i want to just to take the baffles out all together how long do you think it will take me to do?

A trip to Lowes and a couple hours max.

[07custom36]

What do i need to go to lowes for i think i have all the tools i need in the shed to do this project. I have the saw drill and pliers. what esle do you think i need to do the job beside maybe a trip to the beer store

[84_KZ550_NewB]

Originally Posted by predfan2001

The 900 is EFI so debaffling is ok. I've heard that if you modify the exhaust and intake, you need a power commander (??? I think thats what they're called).

Dang wish I was EFI

[predfan2001]

Originally Posted by 07custom36

What do i need to go to lowes for i think i have all the tools i need in the shed to do this project. I have the saw drill and pliers. what esle do you think i need to do the job beside maybe a trip to the beer store

I think the 3" hole saw and the sawz all is all I needed that I didn't have. Get you some beer and get to it.

[longbeachgary1]

Originally Posted by predfan2001

And what is your problem with me? I feel I am one of the few people here who actually tries to help. I didn't post this how to for me, I did it for the members with 900s.

More people need to participate so I do and you call me a moron and want to get me banned? For what?

Predfan,

Please accept my sincerest apologizes. A spammer had gotten in and spammed a half dozen topics – this one included. I guess my request to have them banned worked. Again I apologize.

[07custom36]

Ok so i took the baffles out all together and let me tell i love the way it sounds it really sounds like a v-twin but the only thing that made me mad was it took me abt 4 hrs to do . But it was well worth it. Predfan thank you so much for all the help. keep up the how to's i need some more ideas to do free, cheap, mods. i am thinking of debadgeing for the next mod. then prolly goin to have the bike painted over the winter. well keep up the good work

[mshumate99]

Originally Posted by 07custom36

Ok so i took the baffles out all together and let me tell i love the way it sounds it really sounds like a v-twin but the only thing that made me mad was it took me abt 4 hrs to do . But it was well worth it. Predfan thank you so much for all the help. keep up the how to's i need some more ideas to do free, cheap, mods. i am thinking of debadgeing for the next mod. then prolly goin to have the bike painted over the winter. well keep up the good work

lots of easy free mods for the 900 on here. Do a little searching and you will find enough to keep you busy for a while

The license plate relocate is a popular one.

[07custom36]

where abouts is the license plate relocate at on here. i mit do that one of these days when i have nothing to do

[mdqueenz]

Great writeup predfan. Any chance you could post a video or sound clip?

I'm contemplating on doing the same mod.

I googled and found the following vid...is this the sound we can expect?

Thanks!

Vulcan 900 Debaffled and Cut pipes - AOL Video

[predfan2001]

I don't have a sound clip of mine, but here's the one that got me going....



He's got that one idling a tad too low

[mshumate99]

Originally Posted by 07custom36

where abouts is the license plate relocate at on here. i mit do that one of these days when i have nothing to do

just search for license plate mod on here. it should be in the results.

[cruiserone]

Originally Posted by predfan2001

Total time about 1 1/2 hrs and 6 beers. Oh, be sure to have a strong magnet on hand. There will be a bunch of metal shavings!

That makes me think again - I drilled already 8 holes each pipe and quite pleased so far - But now ...????And really only 6 beers ??

Nearly forgot - nice pics and instructions. Thanks for sharing!!

Cheers from Downunder

[guitardadrocks]

If my wife would let me do this to her new 900, I will use your instruction. Well written!

[pvl1964]

Originally Posted by predfan2001

Ok, I read the "how to" on the Delphi Knowledge Base but I didn't really understand it all which made me a little hesitant about attempting this mod. I was already at stage 1 (screens drilled) but I wanted more sound. I like the looks of the factory pipes and the heat shields are the best so I desided to give it a shot.

First you have to drill the rivets and remove the exhaust end cover. Next I bent the flange of the end of the pipe back with pliers so I could access the pipe for cutting. Here it is after I cut it off:



Next get a sawz all (recipricating saw) with a good quality metal cutting blade and cut off the pipe. It worked better for me cutting from the bottom for some reason. Here's what it looks like with the flange removed:



At this point I drilled 8 23/64" holes (that's the biggest my drill holds. Punched and pilot hole drilled first) in the baffle caps but there really wasn't that big of a sound difference so I got a 3" bi-metal hole saw and started cutting the outside of the baffle cap. I wasn't really sure how far back to cut but I'd say go back around 1/2" or so. I didn't have a 1 1/2" hole saw that would work (mine was too shallow) on cutting out the inner part so I drilled 8 more holes inside of the ones I already drilled. From there I got a chisel and popped the pipe loose. So keep in mind, at this point I have basicly just drilled all the way around the baffle cap. There it is with the inner pipe loosened up:



This is where the work and cursing comes in. It's not that bad though. You know when you cut the baffle cap with the 3" hole saw? That was to make it thin enough to rip it out. Yes rip it! Bend it, pull it, pry it..but it will pop loose. Now the pipe that is left there in the center is welded on the far end. It has to be broken loose but the only room you have to move it is the inner diameter of the pipe. I grabbed an old wood paint roller extension and crammed it up in the pipe and started bending. Go up and down, side to side. When it is ready to come out you will hear a "pop". That is when the metal has broke loose from you bending it back and forth. It may take 5-10 minutes but don't give up! Here's what you have when it comes loose:



Now I'm baffless and it sounds pretty good. Not too loud but at least I can hear the exhaust at highway speeds rather than knocking, whining and whistling. I was scared it would really be loud but it's not....about right I'd say.



Oh and here's the scrap pile left over:



Not that it really needed it but I did like everybody else and scuffed the inner pipe and gave it a shot of high-temp black paint:



Total time about 1 1/2 hrs and 6 beers. Oh, be sure to have a strong magnet on hand. There will be a bunch of metal shavings!

Hey Predfan, I may have already asked this (and missed the reply) but did you feel any extra power after the debaffle? Also, do you think a power commander (or the like) would be a benefit? Could you PM me so I don't miss the reply again.
Cheers.

[Shifter85]

Hey Predfan and others who might know,

I own the exact bike, If you compared the stock debaffled, to say the Cobra Dragsters or V & H with baffles, how much of difference in noise/quality of the noise?

I would love to save some bucks, but still get the sound I'm lookin for.

Thanks,
Still a newbie
Shifter

[predfan2001]

I've never heard any other pipes so I can't really compare.

I didn't notice any power loss or gain. Of course the illusion is there because it's louder. Mpg appears the same.

[guitardadrocks]

"Next get a sawz all (recipricating saw) with a good quality metal cutting blade and cut off the pipe. It worked better for me cutting from the bottom for some reason."
I'm not understanding this part. Are you cutting the external pipe or internal?
Thanks!

[07custom36]

guitardadrocks you are cutting the inernal pipe i did this mod last week and let me tell you i am very happy with the out come