Exhaust - original mufflers gutted

[frenchgixxer]

Decided to try to debaffle the original canons. The bike has delkevic headers and collector and I would really have liked to put their 230mm oval carbon shorties on (looks, sound and weight saving) but they would have cost about 30% of what I paid for the bike so was hard to justify. If 20% I'd have gone for them, however.....

Not much info really on this mod. Jacog video on you tube but, as it turned out, that was very "economical" with the effort needed! A reference in the forum from milts and speedy but that was about it. The canons were not pristine so thought what the hell. In brief:-

1. Remove exhausts
2. Drill out the 2 rivets holding the end cap on
3. Use a 44mm hole saw to cut through the first outer weld
4. Unless you have a long hole saw the standard size will be too short to reach the inner one (about a cm inside) so cut the tip off for clearance - I used a dremel
5. Cut through the 2nd weld
6. The baffle will still not move as there is a 3rd weld where the baffle is joined with the deflector baffles about 6 inches inside. So I took a chisel and just kept bashing with a lump hammer till it moved freely - maybe 30 mins
7. Put a rod into the baffle and now just wiggle in all directions until that inner weld is finally broken - maybe another 30 mins
8. And still the baffle won't come out as the weld bead, on the inner side of the 3rd weld, catches. So crow bar, or similar, on the top neck of the baffle and push/hammer till it pops and then wriggle the baffle out
9. Tidy up rough edges
10. Re-rivet end cap. Unlike Jacog, I didn't feel the need to put another home made baffle back in.

Overall, I think it looks ok and definitely sounds much better (louder!)

Would I recommend doing this? Not if you have/want pristine original silencers on your bike as they will, inevitably, get dinged up a little with all the physical abuse needed to remove the baffles, talk about suzuki over engineering them!

[frenchgixxer]

How can I load a short video of the sound? File says 10.4MB so too big to add? Thanks

[Jeykey]

Tried doing this on the K5 single can but couldn´t do it. I suppose it´s welded way down where the exhaust is at its straightest. Still in the garage for a further project. Even contacted a laser cutting company but still waiting for a reply. Would cut the can at that point and resolder with laser again.

[frenchgixxer]

Tried doing this on the K5 single can but couldn´t do it. I suppose it´s welded way down where the exhaust is at its straightest. Still in the garage for a further project. Even contacted a laser cutting company but still waiting for a reply. Would cut the can at that point and resolder with laser again.

Yes, its welded lower down - see attached pic (the lower weld point is at the bottom of the left hand side baffle). To remove I put a chisel down the inside of the baffle, and hit it with a hammer, back and forth. It moves and loosens, after maybe half an hour the weld will move back and forwards freely enough and then I put a longer bar down the baffle and just waggled it side to side and in a stirring motion until the baffle broke away completely, maybe another 30 mins. Then you have to ease the baffle out as the weld, on the underside of what has just broken away, may catch a bit. So, yes it is do-able. I'd attach a short sound video but don't know how to compress to the 1MB size limit for the forum

[froudy]

Upload the video to YouTube and then post the link to it on here

[frenchgixxer]

Upload the video to YouTube and then post the link to it on here

Ah OK. Never done that before, I'll give it a try, cheers

[Jeykey]

@frenchgixxer thanks for the feedback

[VladTepes]

Upload the video to YouTube and then post the link to it on here

Ah OK. Never done that before, I'll give it a try, cheers

If you have trouble or don't have a youtube channel, let me know and I can upload it somewhere and link to it.

[frenchgixxer]

Upload the video to YouTube and then post the link to it on here

Ah OK. Never done that before, I'll give it a try, cheers

If you have trouble or don't have a youtube channel, let me know and I can upload it somewhere and link to it.

Thanks Vlad. I don't have a you tube channel so not sure where to load it too so I can link here

[paulr5604]

Upload the video to YouTube and then post the link to it on here

Ah OK. Never done that before, I'll give it a try, cheers

If you have trouble or don't have a youtube channel, let me know and I can upload it somewhere and link to it.

Thanks Vlad. I don't have a you tube channel so not sure where to load it too so I can link here

Any joy with the video tempted to do this to mine but would be interested in hearing it first

[frenchgixxer]

Right, finally a link to you tube with a very short video of debaffled canons. I'll take a better one once I've worked out how to operate my new phone - first new one in 8 years lol

is3h0lhKT4A

[paulr5604]

Thank you

What is it like when riding?

[frenchgixxer]

Definitely louder than stock but not as loud as mufflers from the likes of delkevic and blackwidow. TBH at speed its more wind roar anyways which is why I usually ride with ear plugs if going any distance.

If you're going to try to debaffle then, if you can, get a cheap, non pristine, spare set and modify those.

[seth]

@Speedy1959
You did this with your old bike 

[paulr5604]

Definitely louder than stock but not as loud as mufflers from the likes of delkevic and blackwidow. TBH at speed its more wind roar anyways which is why I usually ride with ear plugs if going any distance.

If you're going to try to debaffle then, if you can, get a cheap, non pristine, spare set and modify those.

Thank you for the info. Mine are not pristine anyway and if they are not as loud as delkevic one's then I think it won't be an issue