Complete De-baffling of VN 900 Exhaust

[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!

[CycleDude]

Originally Posted by predfan2001

Total time about 1 1/2 hrs and 6 beers.

Bike looks good, only why so few beers?

[cdnielson]

I never did end up doing the black paint on mine even though I did scrape it up badly.

[predfan2001]

A couple people have asked me about the 3" hole saw....is it really required? I was just going by the Delphi site "how to", but I guess it may pop off with a little more effort as long as the inner pipe is cut loose.

A couple people here have posted that they used a smaller hole saw to get the inner pipe loose and then removed the baffle cap.

So is grinding down the outside of the cap with a 3" hole saw really doing anything? I don't know but it worked for me.

[longbeachgary1]

Please Note That My Post Was In Reference To A Spammer Who Had Posted In A Half Dozen Topics. It Was Never Intended For Predfan 2001. My Apologizes To Everyone Involved.

[El Mexicano]

Very good article. I wish I would have known this before I bought my Cobra pipes

[predfan2001]

Originally Posted by longbeachgary1

Can we get a moderator to get rid of this moron?

Response directed to a spammer. The deleted entry caused a little confusion. Sorry guys!

[mshumate99]

Originally Posted by longbeachgary1

Can we get a moderator to get rid of this moron?

Who exactly is this person and why would he make a comment like that?

This is a great how to posting.

[sbg8r]

predfan great looking bike good to see that it worked for you.....are you happy with the sound???

[predfan2001]

Yes, very! It's audible now but not too loud. I really wouldn't want it any louder, my neighbors would hate me!

[07custom36]

I am considering on debaffling my 07 vulcan 900 custom. i just am wondering how much of a difference in the tone it makes. does it make it deeper or what?

[mshumate99]

Originally Posted by 07custom36

I am considering on debaffling my 07 vulcan 900 custom. i just am wondering how much of a difference in the tone it makes. does it make it deeper or what?

On mine it is deeper yes.

[07custom36]

when you say deep is it nice sounding deep or is it annoying deep. cause i have heard some bike that got debaffled and they sounded terrible but then i have heard some that sounded great. i am hoping the 900 is one that sounds good

[predfan2001]

The easiset way I can put it that after you debaffled it, you can actually hear it run. No engine noises at highway speeds, just a mellow exhaust tone. When you rev it, it sounds like a v-twin and you will have no problems with stalling because you can hear the rpms.

[07custom36]

OK that deff sounds like i really want to do it now. i think i mit do monday. i will let everone know how i like it

[El Mexicano]

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?

There is a big misunderstanding PredFan. Please excuse my friend Gary but he is not talking about you. There was another comment above his where a newbie (the moron he's really talking about) is spamming your thread. I was the one that reported the spam and the moderators removed the comment, which now makes it appear as if Gary is talking to you but he is not. Sorry for the confusion. I am sure he will apologize once he sees what happened.

[predfan2001]

Oh, I see that name "trikebubble" in the comment now that you mention it. I guess that was who posted the comment that got deleted. I see now.

Sorry guys I was just wondering what I could have said to get a response like that. It's cool that you reported stuff like that, I do the same.

[El Mexicano]

Originally Posted by predfan2001

Oh, I see that name "trikebubble" in the comment now that you mention it. I guess that was who posted the comment that got deleted. I see now.

Sorry guys I was just wondering what I could have said to get a response like that. It's cool that you reported stuff like that, I do the same.

We all appreciate you taking the time to write how-tos like this one. Please don't be offended.

[predfan2001]

I'll try another as soon as my lowering kit gets here.

[Shifter85]

Great pics and info Predfan, this will be a huge help and save me some cash! Thanks, Shifter