Bonneville America Forums Forums Technical Forums Exhaust baffle removal tool....

...just finished making a "tool" to remove (at least) the rear baffle in my America....as you can see, the I.D. of the pipe very closely matches the O.D. of the baffle's tube, so this is what will pilot the cutter.....the hole saw is 2 1/4" and the whole thing has a 1/2" drive for chucking in a hand drill....

Looks nice! I'm wondering how it will work on the inner baffles because I think they are somewhat off center, am I wrong? Definitly a fine piece!!

I made one with a 2 inch hole saw. Worked good, looked like heck. And yes the inner baffles are off set from center

I realize that the inner baffles are off center, but my intention is to remove the rear baffles and drill two half inch holes beside the tubes in the next baffles......not looking for drag pipes, just a bit of rumble... I did buy a set of "take off's" on ebay....just in case I need to make it sound like a sewing machine again....

It must be the name Michael! I made several giant holesaws using same size holesaw/tubing. The 1-1/2" went all the way thru my Speedmaster pipes by slicing the offset tubes lengthwise. It fit the outlet end of the muffler perfectly. I also made a 1-1/4" that works fine for the America's. Slicing thru the offset tube is a pain and takes patience, but can be done. I just kept removing pieces till I got the sound I wanted: turns out I pulled them all out except the tapered cone at the very front of the muffler. I also have a set of stock pipes that are ready if those black helicopters start following me again.

Mike Sr.

Michael, you will probably be very happy with the sound from just one baffle removed!

....well, the rear baffle removal was very neat and simple!....the tool cut as intended and the bike has a very nice deep rumble at idle....I'll have to ride it a bit to evaluate the sound at cruising speed....

You are right on track. If you decide to drill the 1/2" holes in the second baffle, do them one at a time and "force" yourself to go for a ride between each new hole. Every one you add will change the sound. I stopped at 4 which is perfect for me. Much louder than stock, much quieter than any aftermarket pipe I've heard.

Todd.....did you need to re-jet after rear baffle removal and four half inch holes in the next one?....

I re-jetted to be on the safe side. I forget what I went up to... 135s I think? I have em out in my garage somewhere if you want me to check.

Michael thanks for the picture and MikeSr thanks for the earlier information. Mike why do you think you have to re-jet? Bennybmn why did you say "to be on the safe side?"
How long is the tube that the cutter is attached to and and how does it fit to a drill?

I ran it a day or two without rejetting, but I was affraid I was running lean, which I hear is worse than running a little rich, so rather than generating too much heat, I figured it was safter to re-jet and get the mix right. Turns out I picked up a few ponies too!

Benny....so far, I have only removed the rear baffle...massachusetts state inspection is this month, so I am reluctant to go any further until I have that sticker on my plate....I would love to know the size of the jets that you ended up with....and by the way, mine is a black & silver '03

I did not re-jet. Other than AI removal, all I've done is back the pilots out to 3 turns. The bike runs really strong as is and I've had no indication of lean running.

I do plan to have a dyno run with exhaust analysis done soon just to see if there's more to be had with a jet change. However, I'm reluctant to give up any MPG as the bike's range is already so painfully short.

Hey Michael, looks like I went from 120's to 125's and stayed with 42 mains (I think that's stock right?). So where in MA are you again? I'm headed to Worcester for the weekend for sis' graduation, maybe I could drop em off for you? That is if you want to re-jet... I don't need em anymore since I freaked.

I'm in Amherst; a long way from Worcester, but I plan to be in auburn on sunday afternoon for the British Iron swap meet. http://www.massbia.com/home.htm Auburn is very close to Worcester and this is always a good meet...

Ok well I'll toss em in the car and we'll see. If we don't meet up I can just mail em to ya no problem.