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Tips for De-Bafflers
  • Use "Bi-Metal" hole saws, the saws for wood will just disintegrate.
  • Keep bending with the dowel until the center pipe is flopping loosely in order to get a clean break when you twist out the baffle.
  • I completely destroyed the cheap drill you see in the video (smoke, then leaking fluid, finally the chuck twisted off!), consider using a model with a little bit of torque. I replaced mine with a Bosch 5.5 amp, and it worked nicely.
  • Be safe; Put the bike in gear, make sure the side stand is fully extended, wear safety glasses when drilling, keep your work area clean.
  • The information here is provided for educational purposes only. I do not advocate performing this modification and take no responsibility for your choice to do so. The VL800 Owner's Manual states on pp. 83:

    TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
    Federal law prohibits the following acts or causing thereof; (1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any devices or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
    Among those acts included in the prohibition against tampering are the acts listed below:
    - removing or puncturing the muffler, baffles, header pipes [...] or any other component which conducts exhaust gases.

    Please proceed at your own peril.

    • Have fun!



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