Baffle removal (Not as hard as they say) - Yamaha Star Stryker Motorcycle Forum
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Old 05-07-2013, 09:29 PM   #1 (permalink)
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Default Baffle removal (Not as hard as they say)

Alright I removed my baffles today. After much reading and concern over how hard people were saying it is I went ahead and did it. It wasn't that bad (in my opinion). Here is what I did and perhaps it can help...

1. If you haven't already drilled holes in the outer baffle plate drill 8- 1/2" holes around the exhaust outlet. Make it easy on yourself and use a pilot bit and a center punch.

2. Using a step drill cutter bit make each hole larger but not big enough to cut into the chrome tip of the exhaust.

3. I found that the metal of the plate is soft enough to cut with wire snips. Snip the metal that is left between each hole.

4. Now the baffle should be able to be moved side to side easily. Get a 12" drill bit extension. If you shine a flashlight inside of the exhaust pipe you should see the other baffle plate. Look closely and there is a ridge of metal that sticks out. Drill right below that with your pilot bit (it holds the bit from going too far up.) Drill about 8 pilot holes around the baffle and then use the 1/2" bit to make the holes larger.

5. Use a large cold chisel and a mini hand sledge hammer and cut the metal between each hole. Once the metal is cut the baffle should pull right out of the exhaust pipe.

I found that this took maybe an hour? Pretty easy I thought.

I will be using a dremel tool with a grinding bit to finish out the end of the exhaust. Shouldn't be too bad since the metal is soft.

Hope this helps!
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Old 05-07-2013, 10:26 PM   #2 (permalink)
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Hey Patrick- Nice writeup, Now wait till ya tackle that Cat Converter Removal!!
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Old 05-08-2013, 08:24 AM   #3 (permalink)
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2 screws and the chrome tip comes off. Better to remove it than damage it.
Good write.
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Old 05-08-2013, 10:31 AM   #4 (permalink)
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Is this ear bleeding loud or just minor annoyance loud?
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Old 05-08-2013, 10:16 PM   #5 (permalink)
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I just drilled eight 5/8" holes in each baffle plate, and I think the sound is just below annoyance. (My kid says it's too loud, but what does he know!!) Plus there is no backfire, (there is some nice popping on decel)
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Old 05-13-2013, 05:13 PM   #6 (permalink)
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I just finished pulling mine, and It is quiter than all of my old bikes.
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Old 05-13-2013, 10:37 PM   #7 (permalink)
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Quote:
Originally Posted by eraser View Post
Is this ear bleeding loud or just minor annoyance loud?
With Cobra pipes and no baffles, it was ear bleeding loud, but now I am used to it, so it does not bother me
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Old 05-14-2013, 09:40 AM   #8 (permalink)
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Huh? Can't hear you LOL
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Old 05-14-2013, 06:00 PM   #9 (permalink)
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Exactly!
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Old 05-14-2013, 07:19 PM   #10 (permalink)
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Quote:
Originally Posted by wes View Post
With Cobra pipes and no baffles, it was ear bleeding loud, but now I am used to it, so it does not bother me
See post above yours lol. I think it sounds great, just don't pull the cat.
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