baffle removal

[n9151]

I have an 01 FI. If I take out the baffles do I need to put on something like a power commander? thanks to all in advance

[v0lusia]

no

No....Unless you've done other mods, like the intake system. Then you'd bennefit a lot.

[n9151]

may seem like a stupid question, but does a K&N air filter qualify for an intake mod?

[radco]

may seem like a stupid question, but does a K&N air filter qualify for an intake mod?
FROM what Ive been told if its the K&N Filter ONLY in the STOCK AIR BOX w/ the No Power comander needed.. I just put the Gutted mufflers on NICE SOUND,DEEPER http://s2.images.proboards.com/grin.gif NOT LOUD,, a mellow rumble. Next is the Gutted Goat belly I have,, I couldnt get 1 mounting bolt off, have it soaking in Penatrating oil. BUT WHEN done,, I ll hear the difference with and w/o the gutted belly..Rich

[n9151]

one last question, where do I find the instructions to gut the mufflers?

[ringadingh]

one last question, where do I find the instructions to gut the mufflers?

Look on Bowndodges Garage for "Bafflectomy" that will tell you how.

Instructions are here: http://kawanow.proboards77.com/?board=general&action=display&thread=529&page=1

[ruruson1]

I have done the bafflectomy and have a K&N filter in the stock box and have had no problems. I also think it has increased my power, or maybe the deeper sound just makes my ego bigger!!!!

[kawgirl]

I have done the bafflectomy and have a K&N filter in the stock box and have had no problems. I also think it has increased my power...

Same here!

[markusmaximus]

one last question, where do I find the instructions to gut the mufflers?

Also check out http://home.insightbb.com/~kpmh.005/N-Gut-Muffler.htm. I used a 1-3/4" hole saw, not 2". I did this 10 days ago and had a helluva time getting the silencers out due to carbon build-up. You may want to have a slide hammer if they seem really stuck. It's worth it. Much better sound.

[kawbuc]

Just took my silencers out Saturday. Started with a HARBOR FREIGHT hole saw. Burnt that hole saw up in about one minute.Went to Lowes and purchased a real Bi-metal 1 3/4" hole saw. Took about 5 minutes and i had them both out. Never used the wooden dowl. Have a variable speed dril and drilled real slow until i got a good groove and then let her rip. Must say , i am glad i did the mod. Now i can hear my bike.Good sound too.

[ringadingh]

I had the same thing happen with Harbour Freight tools,in Canada there called Princess Auto, my 1/2" hammer drill only drilled about 2" into a asphalt driveway and quit hammering. I went and bought a Milwaukee drill. I had the same thing with the holesaws as well.

[rlfaubion]

When I was young Japanese products were looked down upon. Today it's China. Good for a one time use (or less).

[Cajunrider]

I paid $13 bucks for the Rigid 1 3/4" hole saw and another $8 for the arbor at Home Depot. It was well worth it though as it took no more than 1 - 2 minutes to drill each with a Dewalt 1/2" 18v cordless drill. Be sure to use a good cutting oil while drilling.

[scion0]

I'd love to try this baffle removal but not real sure how "easy" it really is as I am not very mechanically inclined. :-)

[ringadingh]

I'd love to try this baffle removal but not real sure how "easy" it really is as I am not very mechanically inclined. :-)
Its as simple as it gets, Drill out the end with a 1 3/4" holesaw and wiggle, pull, pry, beat, the baffle out, either with vise grips or a slide hammer. Blowndodge has instructions on the other board here.

[skeeter]

[quote="ruruson1 #483":iyplbw7z]I have done the bafflectomy and have a K&N filter in the stock box and have had no problems. I also think it has increased my power...

Same here![/quote:iyplbw7z]

What, no ego!

[nomad1600]

I'd love to try this baffle removal but not real sure how "easy" it really is as I am not very mechanically inclined. :-)

Drilling out that baffle is the easiest thing I have done on my bike. It took less that 2 minutes to drill each side out. Just use a big drill 1/2" or larger lots of torque. I used a 1 3/4" hole saw for metal, buy a good one. I then used a 1 1/8" dowel rod from Home Depot and I wrapped it one time over with masking tape, it fit right in nice and smooth. Next use a cutting oil instead of WD-40 it will help cut faster and cooler. Once you have drilled thru just grab the baffle with some vice grips and they pulled right out. I then used a 3/4" drum sander and ran it around the cut and it slicked everything right up. Paint it black and I swear you can't tell that anything has ever been removed.

The low rumble is so Sweeeeeet!!!!! Plus it is a lot cheaper than buying the aftermarket pipes.
Good luck

[billmac]

I understand BlownDodge wrote the book but also Good advice from Nomad 1600. I used WD 40 and a combination wood/metal hole saw. It took longer to drill and I ended up buying another hole saw to do the second pipe.

I painted mine flat black inside the pipes and it looks like it came that way.

I like the rumble and yet still have it quiet at freeway speeds.

[scion0]

[quote=""Scion0" ":5xogxvdg]I'd love to try this baffle removal but not real sure how "easy" it really is as I am not very mechanically inclined. :-)

Drilling out that baffle is the easiest thing I have done on my bike. It took less that 2 minutes to drill each side out. Just use a big drill 1/2" or larger lots of torque. I used a 1 3/4" hole saw for metal, buy a good one. I then used a 1 1/8" dowel rod from Home Depot and I wrapped it one time over with masking tape, it fit right in nice and smooth. Next use a cutting oil instead of WD-40 it will help cut faster and cooler. Once you have drilled thru just grab the baffle with some vice grips and they pulled right out. I then used a 3/4" drum sander and ran it around the cut and it slicked everything right up. Paint it black and I swear you can't tell that anything has ever been removed.

The low rumble is so Sweeeeeet!!!!! Plus it is a lot cheaper than buying the aftermarket pipes.
Good luck [/quote:5xogxvdg]

http://s2.images.proboards.com/grin.gif Thanks for the fast response and words of encouragement. Sounds like a project for next weekend.

I'll let you know how it went.

Thanks again to all that responded. http://s2.images.proboards.com/grin.gif

[ringadingh]

I'd love to try this baffle removal but not real sure how "easy" it really is as I am not very mechanically inclined. :-)
Once you see how easy it is you can try something else. A guy once told me, Hard stuff, is just a bunch of easy stuff all put together. One step at a time and its no big deal, theres lots of good help here.

[scion0]

I'd love to try this baffle removal but not real sure how "easy" it really is as I am not very mechanically inclined. :-)
Once you see how easy it is you can try something else. A guy once told me, Hard stuff, is just a bunch of easy stuff all put together. One step at a time and its no big deal, theres lots of good help here.

Been riding so much lately that I haven't had a chance to try it (hey, it's my story ... ) but hope to tackle it soon.

[coacha]

Before you start, find out what drill not to use by asking davidjones...his burnt slap up in Elkins.

[unwind2]

Before you start, find out what drill not to use by asking davidjones...his burnt slap up in Elkins.

Yep my hard headed Nomad did David's drill in. :-/

[kawgirl]

Did ya git er done yet Nancy?

[davidjones1]

yes I would like to know if my fail attemp was completed. I want you to know that my rep that sold that junk drill took me to lunch and brought me and 18volt replacement after I told how embarassed I was to not finish your baffle removal witch got a wired look but none the less a new drill, I hope Ken did not have to bad a time finishing up.
ride safe.

[unwind2]

Not yet guys - I am still half baffled-LOL. :-/ Ken says to bring the bike to the fire station Thurs afternoon and will see about it then. To be continued. Hey sounds good though even with one in and one out. ;)
http://i207.photobucket.com/albums/bb11/Unwind2/KawaNowEasternRally-113-1.jpg

[cactusjack]

When I debaffled mine, I cooked my Harbor Freight 1/2" hammer drill ($24.99) halfway through the first one, had to run to Home Depot and bought a really nice B&D 1/2" hammer drill and finished up the first one and did the second one in less than 30 seconds. I used a good Craftsman bi-metal hole saw.

[jussmatt]

I used a dewalt corded to get mine done, but I did buy a new set of Rigid hole saws from Home Depot. This being said.... a reminder to all of y'all out there who will perform the bafflectomy.... you CANNOT use enough lubricant!!! That's were it's the hardest on the drills and the saw blades....is not giving it enough WD-40..or whatever you choose to use!! If you think you've put too much on there.... PUT SOME MORE!!!! Trust me..it's not enough!!! I've worked/drilled enough metal to know that you can't use too much lubricant to help keep the blades cool!!!! Just my 2cw!!

[samkjr]

Many of you will notice my post in the mechanical section, but Yes I did just drill mine out tonight and I sure like it. Probably one of the better cost to benefit ratio mads you can do.

60 bucks and an hour compared to 600 or so and maybe three hours.

Definitely worth it. I was just scared to do something like that at first. going slow and careful. Used my wooden dowel onthe first side went slow applied pressure. took about 5 minutes. second side I wasn't scared any more. Did it in about 2 minutes and it looks like a cleaner line. lol

For anyone concidering, does it sound as nice as cobra duals or V&H staights? No, but for the time and cost of this easy mod, it sure is worth it.

[markusmaximus]

Many of you will notice my post in the mechanical section, but Yes I did just drill mine out tonight and I sure like it. Probably one of the better cost to benefit ratio mads you can do. 60 bucks and an hour compared to 600 or so and maybe three hours.

Definitely worth it. I was just scared to do something like that at first. going slow and careful. Used my wooden dowel on the first side went slow applied pressure. took about 5 minutes. second side I wasn't scared any more. Did it in about 2 minutes and it looks like a cleaner line. lol

Like samkjr, my heart was racing when I touched blade to metal. That turned out to be the least of my problems. Had so much carbon build-up, had to use a makeshift slide hammer to get the silencer tubes out. Unlike samkjr, my time to extract the tubes was about 8 hours. But it was worth it.

[scion0]

8 hours -- ouch!! How old is your bike and how many miles when you did the mod?

[markusmaximus]

8 hours -- ouch!! How old is your bike and how many miles when you did the mod?

She's was an 05 with only 3500 miles when I debaffled her. Admittedly, the process would not have taken so long if I had a slide hammer. But I never thought I'd need one, based on all the posts. Live and learn. http://s2.images.proboards.com/tongue.gif

[scion0]

[quote=""Scion0" ":bs28k5cc]8 hours -- ouch!! How old is your bike and how many miles when you did the mod?

She's was an 05 with only 3500 miles when I debaffled her. Admittedly, the process would not have taken so long if I had a slide hammer. But I never thought I'd need one, based on all the posts. Live and learn. http://s2.images.proboards.com/tongue.gif[/quote:bs28k5cc]

Maybe that would not be a bad thing have available, just in case.

[samkjr]

mine is an 07 with 4600. and though stiff. tey were not that bad to pull out. and I was just using some needlenose pliers

[scion0]

mine is an 07 with 4600. and though stiff. tey were not that bad to pull out. and I was just using some needlenose pliers


Going to the J&P Cycle Open House Saturday so I think I am going to 'debaffle' on Sunday....

[ringadingh]

Using a good quality holesaw is the most important item along with lots of coolant, cheap holesaws make a really simple quick job into a timewasting mess. Buy a good holesaw and be done in a few minutes.

[unwind2]

I'm am proud to annouce the birthing of the left baffle. I am now completely debaffled! http://s2.images.proboards.com/grin.gif

[coacha]

I'm am proud to annouce the birthing of the left baffle. I am now completely debaffled! http://s2.images.proboards.com/grin.gif

Hurray for you unwind!

[tkd]

I pulled one of my baffles on my baggers today in hopes that it was time to repack (and quiet it down some) but, alas, the packing was in pretty good shape other than a little discoloration.

I did start the bike with one of the baffles out and it ran like crap----coughed, sputtered, and nearly died.....it really sounded like crap. Back in went the baffle and it purred again.

don't ask me why