taking out baffles???
Outstanding HDF Member
Joined: Aug 2005
Posts: 3,167
Likes: 7
From: FL & SoCal
RE: taking out baffles???
I assume you are refering to the stock baffles. You will have to drill them out in order to remove them. Can't remember off the top of my head the size bit you will need. Take our advice from this forum as many will attest to this recommendation; do yourself a favor, spend the extra money and buy some good after-market slip-ons. Cycle Shack, Vance & Hines, Khrome Werks, and Screamn Eagle's are all better alternatives that are reasonably priced. You will be much happier with the results and the sound. You don't have to do a re-jet but it's highly recommended, will give you better performance and will keep your pipes from blueing since you won't be running so lean. Good luck....
Tourer
Joined: Sep 2005
Posts: 278
Likes: 0
From: Lafayette, LA
RE: taking out baffles???
IIRC you will have trouble drilling out baffles on an 06 - especially the front one, as it has a catalytic converter in it. If you want to drill out your baffles, best get a pair of stocks off an 04 or 05 from ebay and drill the baffles out of those - that way you have your stock pipes intact - which if they ever bring in emissions testing, you'll need those intact for the inspections.
To drill them out, I believe you have at them with a 44mm (1 3/4") hole saw - make sure its made for metal - and drill them out (from the end of the muffler opposite to where they connect to the pipes).
Alternatively, its about 30mins labor at your local indy, my local one said they'd charge around $25 to do it, so its not an expensive mod - stock mufflers, should cost well under $50 including shipping on ebay.
If you are short on cash its a really good way to improve your sound and your outflow. The next step would be to put on something like cycleshack mufflers - but they run around $130 for a pair.
As far as rejetting, it seems to me from what I have gleaned in researching this, is that you won't need to rejet until you change your air cleaner. That said, you won't benefit from improved outflow - either in sound or performance, until you install a high flow air cleaner. They run around $100 for the screaming eagle versions. Now after doing that you will definately need to rejet.
If your bike runs bad for any reason after modifying the pipes - it would be cheaper in the long run to go ahead and have the air cleaner installed before rejetting, that way it only has to be done once, especially if you want it run on a dyno to tweak your tuning.
To drill them out, I believe you have at them with a 44mm (1 3/4") hole saw - make sure its made for metal - and drill them out (from the end of the muffler opposite to where they connect to the pipes).
Alternatively, its about 30mins labor at your local indy, my local one said they'd charge around $25 to do it, so its not an expensive mod - stock mufflers, should cost well under $50 including shipping on ebay.
If you are short on cash its a really good way to improve your sound and your outflow. The next step would be to put on something like cycleshack mufflers - but they run around $130 for a pair.
As far as rejetting, it seems to me from what I have gleaned in researching this, is that you won't need to rejet until you change your air cleaner. That said, you won't benefit from improved outflow - either in sound or performance, until you install a high flow air cleaner. They run around $100 for the screaming eagle versions. Now after doing that you will definately need to rejet.
If your bike runs bad for any reason after modifying the pipes - it would be cheaper in the long run to go ahead and have the air cleaner installed before rejetting, that way it only has to be done once, especially if you want it run on a dyno to tweak your tuning.
Intermediate
Joined: Sep 2005
Posts: 27
Likes: 0
From:
RE: taking out baffles???
Nothing like a picture, to go along with Scooterbooter's description. I drilled mine on the bike. Like the man said, this works on 05 and earlier models due to the cat in the front pipe on the 06's.
After the cut
Removing the baffle
Finished muffler ( 1.75 straight thru glass pack, retaining the stock crossover)
After the cut
Removing the baffle
Finished muffler ( 1.75 straight thru glass pack, retaining the stock crossover)
Outstanding HDF Member
Joined: Nov 2005
Posts: 2,357
Likes: 1
From: Iwakuni, Japan
RE: taking out baffles???
Ram,
Im with WarriorHD, spend a few $$ and get some slip ons. That way you can always go back to stock if need be. And you will be much happier (I feel) with a after market pipe that you can get support for. Rejetting is easier I think as well. You can hit E-Bay and pick up some great deals there. By the time you go buy all the tools ect you ned to drill them out you will have paid for (or almost) a new set of slip ons.
MHO
Geno
Im with WarriorHD, spend a few $$ and get some slip ons. That way you can always go back to stock if need be. And you will be much happier (I feel) with a after market pipe that you can get support for. Rejetting is easier I think as well. You can hit E-Bay and pick up some great deals there. By the time you go buy all the tools ect you ned to drill them out you will have paid for (or almost) a new set of slip ons.
MHO
Geno
Advanced
Joined: Dec 2005
Posts: 82
Likes: 0
From:
RE: taking out baffles???
RamSporter,
I also am with the notion of spending a few bucks and at least pick up some after market slip-ons. You would be much happier with the sound as compared to the stock pipes drilled out.
Like scooterbooter said, you will not have to re-jet a 883 unless you change the air filter to a high flow type. But if I were you, go ahead and get the after market pipes and keep the stocks for who knows what. Because once you drill them out, there's no turning back.
!!! RIDE SAFE !!!
Keith in temp is creeping up in Pa.
05 1200 custom "Lava"
I also am with the notion of spending a few bucks and at least pick up some after market slip-ons. You would be much happier with the sound as compared to the stock pipes drilled out.
Like scooterbooter said, you will not have to re-jet a 883 unless you change the air filter to a high flow type. But if I were you, go ahead and get the after market pipes and keep the stocks for who knows what. Because once you drill them out, there's no turning back.
!!! RIDE SAFE !!!
Keith in temp is creeping up in Pa.
05 1200 custom "Lava"
Trending Topics
Outstanding HDF Member
Joined: Aug 2005
Posts: 3,167
Likes: 7
From: FL & SoCal
RE: taking out baffles???
One would assume if you plan on upgrading to a "freer" flowing exhaust whether you plan on drilling out the stock ones or going the aftermarket route that you'd want to install a high flow air cleaner along with the rejet. I'd recommend doing a full Stage 1 upgrade; meaning after-market mufflers, freer flowing AC and a rejet. There are many posts on the forum on how to get away cheap doing a simple rejet without spending all the money on a full Dyno Jet kit. TCSD could probably point you to the links. Take your time and research what's best for you so you don't just burn away money.
I have done research on exactly what you'd like to do and have learned that by removing the stock baffles on any HD without increasing the intake flow will cause a slight decrease in low end (off the line) torque. I believe this is because of the physics that make up the different gases that exist in back pressure and the volume and capacity of air and fuel flow through the system. I have found many good posts online and in auto and motorcycle books that explain this theory. Whether you can actually feel it in the seat or not, I don't know. However, with the wieght of the Sportster, I'd guess it might be slightly noticable.
It would make no sense to free up the exhaust side of the bike without freeing up the intake side unless you just want more noise. Reminds me of when I was in high school many years ago (lol) and my buddies would would install Flowmaster mufflers on their cars and say, "OMG, It's so much faster"....lol. Yeah right, as if they could feel a 5 HP gain on a 3000 lb vehicle...lol. Chances are, they probably slowed the thing down off the line since they reduced back pressure without increasing their intake capacity.
Good luck once again and consider doing a full Stage 1. We can give you ideas on this forum about does and dont's and how to save some money.
I have done research on exactly what you'd like to do and have learned that by removing the stock baffles on any HD without increasing the intake flow will cause a slight decrease in low end (off the line) torque. I believe this is because of the physics that make up the different gases that exist in back pressure and the volume and capacity of air and fuel flow through the system. I have found many good posts online and in auto and motorcycle books that explain this theory. Whether you can actually feel it in the seat or not, I don't know. However, with the wieght of the Sportster, I'd guess it might be slightly noticable.
It would make no sense to free up the exhaust side of the bike without freeing up the intake side unless you just want more noise. Reminds me of when I was in high school many years ago (lol) and my buddies would would install Flowmaster mufflers on their cars and say, "OMG, It's so much faster"....lol. Yeah right, as if they could feel a 5 HP gain on a 3000 lb vehicle...lol. Chances are, they probably slowed the thing down off the line since they reduced back pressure without increasing their intake capacity.
Good luck once again and consider doing a full Stage 1. We can give you ideas on this forum about does and dont's and how to save some money.
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Tourer
Joined: Jun 2005
Posts: 328
Likes: 0
From:
RE: taking out baffles???
Ditto on doin' slipons vs. pullin' the baffles (which end up sounding like a lawnmower engine on steroids IMHO)... WarriorHD's comment about decreased backpressure and resultant drop in low end power on straight-thru pipes (like a baffle-less stock pipe would behave like, or drag pipes) rings true - in fact, there are follow-up mods to address this. Again, you can avoid all this (raspy sound, power drop) by goin' with a set of slip-on muffs (that can be a lot cheaper than expected, and give BETTER sound and low-end power than stock)...
Good luck!
Good luck!
Tourer
Joined: Jun 2005
Posts: 328
Likes: 0
From:
RE: taking out baffles???
Oh, and if you've got an '06, you've got a cat, so even better to want to keep the stock pipes around for emissions testing down the road. I don't necessarily believe the horror stories of EPA fining everyone $10000 each if they mod their systems (it IS illegal to tamper with things like cats, though) but having the stock pipes around so you can put them back on if you get ticketed or need to be inspected is a good idea.
Good luck!
Good luck!