Vulcan 900 Classic OEM Pipe Debaffle Comparison
A comparison between the stock setup and two DIY mods to the Exhaust system. For more information on how to
modify your Exhaust this way, check
out this thread where I learned how to perform this mod:
Tools you may need:
Corded Drill (cordless may not have enough power)
Metal Punch (to keep drill bit in one place on the surface)
Metal Drill Bit (your choice, I went with a pilot hole and then finished at
1"-3" Hole Saws (Not required but may help)
Metal Pipe 3/4" diameter (to bend inner Exhaust pipe back and forth)
A short video to demonstrate debaffling of a Volusia
Vulcan 900 Custom Debaffled
-- Debaffling Instructions below -- You're on your own.
Anyway, I just thought that I'd have a comparison video before/after
debaffling a Vulcan 900 Custom.
---- You need a cheap drill because you're going to fuck it up($30 at
walmart), 1'' hole saw, 3'' (3 1/4'' for a very tight fit) hole saw bit,
reciprocating was(set on slow) or a drimmel tool, 1'' wooden oak dowel rod
from home depot, ear plugs and a can of high-heat grill/smoker paint.
You will need a small metal drilling bit(1/4'' will do) and drill out the
rivets holding the baffle plate on the end of the Exhaust. Take the plate off. There should be
another plate behind that one and you will either need to cut it off or
bend it back.
Then cut the baffle pipe down close to the baffle wall(metal wall down the
Exhaust pipe) so you can be able to
use the hole saw cutting bits against the baffle wall. You can use a
drimmel tool with a cutting blade to slowly work around the pipe and not
scratch anything or you can use a reciprocating saw set on it's slowest
setting with a metal cutting blade to cut the baffle pipe.
Then drill the baffle wall with the 1'' bit and use the left over baffle
tube as a guide. Then carefully use the 3'' bit to cut out the larger ring.
go slow so you don't jump around and scratch up the inside of your pipe.
Pull out the metal ring you've cut and then jam the dowel rod down the
baffle pipe and crank it around in a circle. Keep moving in a circular
motion for a few minutes and you will feel the welds break and the pipe
will come out.
Now you've debaffled your bike and will need ear plugs to ride down the
If you didn't scratch up your pipes with the drill bit then you can just
clean them out and you're good. If you got a little paint on there from the
drill bit then you can buff it out.
If you scratched the pipes, like me, then you can use some news paper and
tape off the pipes (so you don't be paint on the outside of the pipes and
your motorcycle) and spray the inside of the pipes with a couple coats of
matte black high-heat paint.
How To MOD Exhaust 2009 Vulcan 900 Custom 2 of 2
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This is a "stage 1" MOD of the OEM Exhaust on a 2009 Kawasaki Vulcan 900 Custom. In
this "stage" the cover is removed, the end pipe is sawed off and holes are
drilled in the baffle caps. This is in an attempt to make the sound louder
View the pictures here:
Special thanks to predfan2001 for his write up and to everyone that has
contributed in order to make this knowledge known
Kawasaki Vulcan 900 Custom Debaffled
I decided to debaffle my '07 Vulcan 900 Custom. Sounds great. Way deeper
sound than just the holes drilled in. Didn't take too long to complete.
Vulcan 900 Custom with Vance and Hines exhaust
first winter warm-up. just a quick description of my bike... love it and
hope you guys like it too... please feel free to comment and give some
suggestions as to what else to do and if it fits my personality i'll
consider it... and you're gonna be a douche and trash my bike, well... F@ck
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