Bonneville America Forums Forums Technical Forums Exhaust pipe drilling and other mods for a new owner

I just took possession of a 2005 America and I love it. The forums on the website here have been a wealth of information, but I need some reassurance. I can't afford new pipes right now (need a new roof), but the sound is pretty puny so I've been pouring over the posts about drilling and removing exhaust baffles. I don't want to get too radical, maybe remove the first baffles and possibly drill the second. So, if I do just that is any rejetting (I don't know the first thing about doing that) or any other mods needed? Also, the pipes have already blued by the engine, would I benefit any from removing the AI at this point? Are there any other basic mods that I would benefit from without getting too too involved? Thanks in advance for any suggestions.

Aeiou5,

1: Get rid of the AI go to Brent’s site and buy the removal kit a few bucks. End the bluing before it begins.

2: Easiest way to remove baffles on the stockers:
1: Buy a 30" piece of R-bar at Home Depot $1.50
2: Grind down one end to form a chisel end
3: Each baffle is held in place by three tack welds
4: Using a flash light find the welds easy to spot and line up your home made chisel
with the weld.
5: Using a hammer I have a 5lbs. hand sledge give it a good whack. It will break real
easy
6: Do all three on both sides and start up the bike see if it loud enough for you (one set of baffles on both pipes at the same time)

Most guys stop after removing the second set of baffles the sound is deep and not to loud. Total time 10 to 15 minutes.

You will not have to re-jet do these mod’s.

Check out the Tech Vault section under air filters there are step by step instructions on how to drill (mod) the stock air box that will require you to re-jet, but there are step by step instructions on how to do re-jet there also.

John

You might want to save the AI parts and pieces if bike emissions testing ever takes hold in your neighborhood. Emissions testing is a source of revenue to those who administer it, so the possibility may not be too far fetched.

Where are you?? That'll also depend on what you should do.

If you are in the UK just remove the rearmost baffle and you SHOULDN'T have to change them for an MOT. I got an advisory note that they were a little loud... but didn't fail.

I was also more delicate with removing the baffle.
Firstly I got my dad to do it. He used a normal metal drill and made a circle of holes, then joined the holes up, and got a small grining stone for his drill and removed the excess bits to tidy it up.

And I still have my AI, just in case they start emissions testing bikes here (They all ready do cars)

If they start emission testing bikes in the UK, I should imagine it will cover the bikes from that year, maybe why Triumph are concentrating on the injection models for the future

John,

I'll check it out and thanks. What you suggest for the pipes doesn't seem too daunting of a task. I'll check in the Tech Vault for the airbox mods and rejetting instructions you're talking about, and if I have any questions about that I'll holler.

Gina,
I'm in Texas so I'll keep the AI parts just for safe keeping.

Wayne

John,

The other option a couple of guys on the site have custom made hole saws that were made primarily for the purpose of drilling out the baffles, then all you neen is drill.

All you need to do is post a request in the Exhaust Forum and who ever has it will mail it to you then you mail it on to the next guy who wnats it.

John

Big Poppy,

I'd be game for the hole saw route as well. Should I create a new post requesting that whoever has it mail it to me?

Wayne