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Old 10-12-2005, 02:44 PM   #1 (permalink)
Grandpa Before My Time
 
drgibson's Avatar
 
Join Date: Jul 2005
Bike: 2008 Kawasaki KLR 650
Location: Dallas, Texas Directly above the center of the earth.
Posts: 11,240
Default Found this On a Kawasaki site "Baffles are Gone!"

How to Debaffle Meanstreet Exhaust;
Last things first. I believe there was a performance increase but it could be just the sound made me think so. There certainly wasn't a decrease. After I did it I did check the plugs to be sure it wasn't running lean. It was all good.
I wasn't sure about how it was constructed so I did it the hard way. I'm going to tell you the easy way.
1. Don't try to dremel the end plate weld off from around the small pipe. That's a waste of time. Get a 2-1/2" metal cutting hole saw ($14 at Home Depot) & electric drill. While you're at it get a 4" long piece of 1 1/8" wooden dowel for a guide. Drill a hole through the center of the dowel & put it on the hole saw pilot bit. Now you have a 2-1/2" hole saw with a 1 1/8" guide rod (it's a perfect fit into the small pipe in the muffler). You'll cut through the thin end plate and another baffle wall right behind it. Now you can pull out the main baffel. The saw cut you made is so clean that it needs very little or no smoothing up. A little black barbeque grill paint and it looks like it came from the factory that way. Crank it up & check the sound. If you want more, go to step two.
2. Look up the pipe with a flashlight & you'll see a support for the baffle you just removed and perforated metal screens farther up. You'll need a 2-1/4" or 2-3/8" hole saw and a 12" extension (the 2 1/2" hole saw is too big for this). I found out that my neighbor is an electrician and has a full set of hole saws. Cut out the support and three screens & you have a hollow muffler. I left the goat bladder in and the sound is just what I wanted.


hmmm where did I put that hole saw????