De-baffle the stock exhaust

[dewmanCO]

Ok, so I know if you search here you get quite a few results for de-baffling the exhaust. One of which used to have a video that no longer works. I learn by seeing so I though I'd throw up some pictures of what I did so that those of you who may still have questions and want to see it kind of step-by-step can.

This is on an '08 M109R

First off, the tools:
-Drill
-flash light
-1-1/4" hole saw with drill bit guide
-12" extension
-1/2" drill bit


Now set up the drill for, well, drilling:

The hole saw goes into the exhaust like so:

This might get a bit tricky just because the hole saw might spin funny due to the set screw in the extension, to get around this I just put a folded up piece of paper between the hole saw bit and the female end of the extension to tighten it up so there was less awkward spinning going on (does that make sense?).

Moving on, once you get the bit in there you'll hit the first wall. You can push hard when drilling if you want but know that when the guide bit goes through the baffle the hole saw might catch and spin the drill so hold on tight.

The first two baffles come out pretty nicely on the hole saw. I found that if you push lightly and let the saw grind through it, the baffle came out with the hole saw. You'll want to keep the drill spinning slowly on the way out, that way its a bit easier to pull out and you don't lose the baffle and/or bit:

and:

Now that the first baffle in both exhaust pipes is out you can do the same for the second. The second baffle is a bit harder to get to but just keep heading back in there and you'll hit 'em. When the drill spins smoothly that means the guide bit is doing its job.

The second set of baffles unfortunately didn't come out as easily as the first. No biggie though, thats where the extendy magnet thing helps:


The first set of baffles are on the right and the second set on the left:

I tried to get a shot inside the pipe of the finished product but it didn't work too well:


Any who, that is what I did. I didn't bother to drill the 1/2" holes around the outer perimeter of the main exhaust hole. I think I'll ride her like this for a bit and see if I want more out of her.



I didn't notice a big change in the idle sound but definitely did in the sound during acceleration. Instead of hissing it gives of a nice rumble now, then when cruising at speed it is a bit mild which I personally enjoy (I can still hear myself think which is always a plus). Well, for this mod. Big fan. Hope this helps people or gives people a bit of reference when trying this stuff out.

[N8S109]

i just did this a few weeks ago and it sounds killer....

way better than stock. i drilled 4 holes around the outside as well and Im happy with it there....

[fatblack]

I ran mine like that as well except I drilled out the entire end plate. Sounded fantastic for a stock pipe.

[ObsceneJester]

Thanks dewman, headed to the parts store to get me the right hole saw as soon as they open...

[dewmanCO]

Thanks dewman, headed to the parts store to get me the right hole saw as soon as they open...

For sure, happy to help.

[Packrider]

That was so easy and it sounds awesome. Got all 6 plugs out without a problem. It sounded OK after that but the 8 holes in the end wall made it perfect.

[Converted]

So... what I'm reading is there is no need for a fuel management system; when de-baffling and drilling 1/2 inch holes? Is this correct?

[dewmanCO]

correct

[GeorgiaRoller]

I just joined the debaffling club. I used the 1-1/4" hold saw method with an 18" extension and drilled through all three baffles on each pipe (6 pieces total) and also drilled 7ea. 1/2" holes in the end as well. I then sprayed the new cut holes with black Rustoleum High Heat paint.

Started it up and at idle it's still mild sounding. But give it a handfull of throttle and it's got much more bark. Still not as loud as I was hoping for but much better for sure. The tone sounds more like a racecar exhaust than a HD. Nice sporty rumble to it now.

Here's my parts list and what I paid to do the job:
- 18" Irwin Speedbor Extension $17.97 (Lowe's)
- Ridgid 1-1/4" Bi-Metal Bit $10.94 (Home Depot)
- Hitachi 1/2" BlackGold Drill Bit $9.97 (Lowe's)
- Hillman 25" Telescoping Magnet $3.97 (Lowe's)
- Can of Rustoleum High Heat Paint $6.77 (Lowe's)

Total $49.62

I used my own 1/4" Guide bit that I had at home for the center of the 1-1/4" metal hole bit.

[Bru'sM109]

Awsome. Thanks for the list.

[Easy E on a 9]

So... what I'm reading is there is no need for a fuel management system; when de-baffling and drilling 1/2 inch holes? Is this correct?

What if you debaffle and just put K&N filters in a stock box?? do u need a fule management system then??
E

[Aus_Lefty]

Great website.
I did similar to GeorgiaRoller and drilled out the 6 baffle plates. I have not done the 1/2" holes in the end yet but it sounds much better than stock. My guide bit came loose and fell out inside the exhaust but lucky it was the top one and I was able to take it off and shake out the bit - this is not the case with the bottom exhaust as it does not disconnect...

[corvettegbert]

What if you debaffle and just put K&N filters in a stock box?? do u need a fule management system then??
E

Yes - You will need the Power Commander if you do both the exhaust and intake mads. These were the 1st mods I did and loved the results.

[crossq]

Thanks Dewmanco, I will be head to the hardware store to pick up some additions to my drill set and start getting this baby breathing !!!!! I am also about to change my clutch and thinking about going with a aftermarket cycle house high performance with MTC springs... any suggestions ??

crossq (crossf78@gmail.com)

[ssbn655]

Thanks, great sound and only spent $40 total. Two walls and four holes on each pipe. Was able to use a 10" extension. Maybe as I get older and my hearing is going away I'll get to 8 holes. This sight has been great for how to's and finding parts.

[bobsc109r]

Hello all, just purchased a new c109r and i want to debaffle the pipes. Has anyone done this to their c109r ? How many walls is there, what tools do i use and how should i do it. I live in Hagerstown md and i'm willing to travel some if anybody is willing to help me. I really dont want to screw this up. Wife is like DONT YOU DARE DO THIS, IM LIKE Riiiiiiiiiight honey. Thanks all

[Bejar]

Thanks..... I purchased my M109 a week ago and I'm so glad there is a webpage like this, doing the debaffle of my bike was so easy following the steps you all log here. I'll keep checking the "How to, step by step" board to see what else I can do to my M109R....

Once again ... Thank you ALL..!!!

[Torn]

Just went to pick up parts for this at lowes..and they only had 10 inch ext....would that work for two baffles?

[assentingsilence]

I'm considering doing this mod this weekend. We shall see if I do and if I like it. I'm not much of a mechanic so I've got to keep this thread up for pointers.

To those of you who have done this and posted about it...THANKS for all the info!

[AFelix]

I think there needs to be an official clarification of terms. Drilling out baffles VS Debaffling. I believe that I have debaffled my exhaust (see attached pic). Prior to debaffling I had done several versions of drilling out the baffles. In the pic the hole you see is were the primary enters the muffler, my cat and crossover are intact, otherwise it is a straight pipe.
If you want LOUD and deep sound especially when you get on it, then you need to debaffle. At idle, it sounds good, and the neighbors are not going to linch you, but if you snap the throttle or get on it under load this thing flat rours. When I start it next to cars with alarms, it sets them off.

[She's real fine my 109]

Been saying it for years. Four years later and every body finely caught on. And yes its a nice deep sound.

[yellow109r]

Yeah I gutted mine out bc I did the baffle and then the four then 8 holes It wasn't what I was looking for the I decided to gut it but the 08 models have I different baffle system and it was a PITA to do but after talking to a couple guys I used I air hammer with a chisel and got it all out finally

[misled]

So I drilled out the first 2 pair of baffles . I havent drilled the 1/2 inch holes yet . Its a huge improvement but maybe Im lookin for just a *little* more . I am considering drilling out the 3rd baffle ( last pair ) before I do any drilling of the 1/2 inch holes . Any sound to be gained from the last baffle removal ?

[She's real fine my 109]

This post here is for de-baffle not drill. We rip the baffles right out.

[Buzzcut]

I gutted mine completely....next step, 3 inch pipe welded into the 3 inch hole and pushed all the way up to the inner pipe. I hope it sound like the hounds of hell set loose.

[Vcrabill]

Ok, so I know if you search here you get quite a few results for de-baffling the exhaust. One of which used to have a video that no longer works. I learn by seeing so I though I'd throw up some pictures of what I did so that those of you who may still have questions and want to see it kind of step-by-step can.

This is on an '08 M109R

First off, the tools:
-Drill
-flash light
-1-1/4" hole saw with drill bit guide
-12" extension
-1/2" drill bit


Now set up the drill for, well, drilling:

The hole saw goes into the exhaust like so:

This might get a bit tricky just because the hole saw might spin funny due to the set screw in the extension, to get around this I just put a folded up piece of paper between the hole saw bit and the female end of the extension to tighten it up so there was less awkward spinning going on (does that make sense?).

Moving on, once you get the bit in there you'll hit the first wall. You can push hard when drilling if you want but know that when the guide bit goes through the baffle the hole saw might catch and spin the drill so hold on tight.

The first two baffles come out pretty nicely on the hole saw. I found that if you push lightly and let the saw grind through it, the baffle came out with the hole saw. You'll want to keep the drill spinning slowly on the way out, that way its a bit easier to pull out and you don't lose the baffle and/or bit:

and:

Now that the first baffle in both exhaust pipes is out you can do the same for the second. The second baffle is a bit harder to get to but just keep heading back in there and you'll hit 'em. When the drill spins smoothly that means the guide bit is doing its job.

The second set of baffles unfortunately didn't come out as easily as the first. No biggie though, thats where the extendy magnet thing helps:


The first set of baffles are on the right and the second set on the left:

I tried to get a shot inside the pipe of the finished product but it didn't work too well:


Any who, that is what I did. I didn't bother to drill the 1/2" holes around the outer perimeter of the main exhaust hole. I think I'll ride her like this for a bit and see if I want more out of her.



I didn't notice a big change in the idle sound but definitely did in the sound during acceleration. Instead of hissing it gives of a nice rumble now, then when cruising at speed it is a bit mild which I personally enjoy (I can still hear myself think which is always a plus). Well, for this mod. Big fan. Hope this helps people or gives people a bit of reference when trying this stuff out.

I just did this mod to tide me over until I get a set of scorpion tips. This was a great help and my bike sounds great. Just to let you and everyone that reads this know. An 06 has 3 baffle walls in each exhaust. So you will have to use 2 12" extentions to do this mod on an 2006. Thanks

[rockey]

Ok, I shouldn't have drilled out the baffles.

My gas mileage has decreased.

More people are looking.

Beast doesn't want to sit still.





May have 16 holes by tomorrow.

I'm not sure if it's actually quicker but I do seem to twist the throttle a little farther.

[delmillar40]

I have a 2006 with stock pipes. It was too quiet so I read all the information on this thread which was very helpful.

I drilled the two baffle walls out like the great instructions and photos said but there was still a third that was over 10 inches in the pipe. I bought a second 12" extension and joined them together and drilled them.

I also drilled the 8 1/2" holes around the base plate.

Its pouring down outside so I haven't been for a big ride yet but so far I love the sound.

Thanks Very much

So you will have to use 2 12" extentions to do this mod on an 2006. Thanks

[MalM109R]

Just did mine an hour ago and sounded loud. but not when in high speed though.Which is great as it will not impaired my hearing during long rides. BTW, we do not have extended bits for the drill bits so I modified a square bar to be used for drilling. It got stuck twice in the hole and broke once too.In the end I am glad it got the job done.

[antman]

Great post! I just finished it, sorta. It took me FOREVER to find the right tools. But anyway, I have an 08 and I drilled out the two baffles in the top pipe, however one of the pieces i drilled out AND the drill bit that broke off disappeared somewhere inside the pipe! (Will this hurt anything? ) On the bottom pipe I drilled the first baffle, and drilled, and drilled, and drilled, got what looks to be all the way through but it wont budge. So i drilled and drilled and drilled and well nothing. Well the nine does sound alot better than stock but be careful riding behind me cause a drill bit might come shootin out at ya