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Discussion Starter · #1 · (Edited)
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, :a18: for this mod. Big fan. Hope this helps people or gives people a bit of reference when trying this stuff out.
 

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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....
 

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Soooooo Easy

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.
 

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Yep, I just did the 8 1/2" holes in the end wall and that sounds good to me. The exhaust should come from the factory sounding like this. IMO. :bigthumbsup:
 

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09 M109R LE

Just drilled out the insides. I used a hole saw to cut out the back plate also, used a drimmel tool to cut the extra tube down, I recorded it and took pics, the audio sucks. I'll post them when i figure out how too.I like it, its a little loud but not terrible. Imo these bike need to sound like this, to look like they do and sound like that stock is unjust.
 

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How did the baffle drilling affect performance? I have done the 8x1/2" thing already, but don't want to lose any punch. I bet it sounds way cool.
 

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just for peoples reference

the 09's are different to earlier models

i tried to debaffle and only 1 baffle from each pipe was able to be removed

so i put holes in the end caps

imho sounds ****house @ idle (sounds how it should but i dont like it, but hey its a short stroke twin crankpin twin, so it will never sound like a long stroke single crankpin V twin)

but ride it and its awesome, sounds bloody fantastic!
 

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Discussion Starter · #16 ·
You shouldn't have messed anything up. Take a nice bright flashlight and shine it down the exhaust and see what's in there. If you made it through the baffles you'll be able to see past them and you should be able to see where they end.
 

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With a little effort it can out perfect, sounds great. three hours later i rode to the gas station and came in contact with another M109 rider, we began to talk an I told him about the mod and cranked it, he was blowed away he said he was going to look in to it so I gave him the website. Just passing the message on to another brother. thanks for a great thread.
 

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I finally drilled out the baffles yesterday. It took longer to get the tools together than it did to complete the job. I think it took less than 15 minutes and all four baffles were out.

For those that are taking a long time to get through the baffles with the hole saw; be sure you are using a bit that is designed for metal. When I bought mine, the hole saw bits were all hanging in the same area and I just grabbed a 1 1/4". As I was standing in the check out line (Black Friday = long line...) I noticed that the bit was only for wood. I had to go back to get the right bit and ended up at the end of that long line again.

I actually like the look of the stock exhaust and the tone is now better than it was before the mod. I may still end up with some HC Sideburners, but this will keep me happy for a while. :bigthumbsup:

Smitty
 

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Very nicely laid out...great photos...

I have one question, though...can you guys describe to me as best as possible how this sounds when you are done?

The reason I ask is, I don't want my bike sounding like a Milwaukee Paint Shaker (HD) and then when I open the throttle, sounding so loud it wakes the entire neighborhood up.

I wouldn't mind it sounding throatier, but want to avoid it sounding like a really loud and obnoxious HD.

Thanks

Chip
 
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