Today I decided the exhaust was too quiet and needed to fix the problem. Solution? Custom race baffles. Half straight pipe and half baffled. I got tired of seeing a ton of thread with pics scattered all over the place and everyone asking for videos so here you go. A walk through, pictures, and before and after video. Heres a little walk through of what i did. Companies sell the race baffles for $90 for a kit, well i made my own for under $20. I designed mine to flow freely and to be decently loud... so here we go!
Remove the upper tail fairing
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Unclamp the exhaust at the Y-pipe
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Take off the plastic covers and take out the screws supporting the upper portion of the exhaust
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Take the exhaust off.
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Take a 3/16 drill bit and drill out the 6 rivets on each can. Once there drilled out slide off the tips
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Now take a center punch and punch in the center of each of the 4 spot welds on each can. Then drill a pilot hole and work up to a hole that is large enough to drill out the entire spot weld. The spot welds hold in the factory baffles. Once drilled pull the baffles out
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The stock baffles are so restrictive
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It got a little beat up pulling it out
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Next i cut out 2 7in by 16in squares of 20 gauge perforated metal. The baffles need to be 2in in diameter. Well circumference equals 2*pi*r or d*pi... 2*3.14 = 6.28 and about 3/4 of an inch left over for overlap.
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Next i rolled the steel around a 2in pipe. Its pretty hard but persuasion with a rubber mallet works well.
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To keep its form i used galvanized safety wire.
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This is completely optional. I like loud exhausts so i did it. The more area of perfoated steel left open the quieter the bike will be. The more area covered the louder it will be. I covered roughly 8in with aluminum tape found at any ACE or Home Depot in the heating and cooling area.
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Next i cut the end of the pipe to match the angle of the stock exhaust covers
![Image]()
This now is a goof oportunity to use a high temp paint on your cans if you want them black. Wash them off well and paint!
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Next your going to need 2 packs of 4 stroke muffler packing found at Cycle Gear. I cut two 1 in strips and two 2 in strips and used the rest as the wrapping. Because the exhaust is an oval shape i put the 1 in strips on the sides. I then rolled the large piece over them to get the oval shape. Then i took the 2in strips and put them on the sides. I then took safetly wire and wraped it all together so it wouldn't fall apart when putting them into the stock cans.
![Image]()
Next slide your new baffles into the stock cans. Make sure they line up with the inlet of the can and the tip lines up with the outlet. Now slip the stock end cap back on. Now use 3/16 aluminum rivets to put it back together. Once together mount it mack on the bike
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Repeat with the second can and you will be done. This is a pretty lengthly process and there are many ways to make your own baffles, so do what you want. Just know that the baffle must me 2in in diameter.
Now what do you think will flow better?
Something restrictive like this:
![Image]()
Or something free flowing like this:
![Image]()
Heres some before and after video..
Before with gutted cats..
After with race baffles and gutted cats..
Again this is a cost effective mod that allows you to save hundreds of dollars on after market exhausts for 04+ R1's. The is exactly the same design that two brothers, Yosh, and the companies use. Its just a free flowing exhaust!
Remove the upper tail fairing
Unclamp the exhaust at the Y-pipe
Take off the plastic covers and take out the screws supporting the upper portion of the exhaust
Take the exhaust off.
Take a 3/16 drill bit and drill out the 6 rivets on each can. Once there drilled out slide off the tips
Now take a center punch and punch in the center of each of the 4 spot welds on each can. Then drill a pilot hole and work up to a hole that is large enough to drill out the entire spot weld. The spot welds hold in the factory baffles. Once drilled pull the baffles out
The stock baffles are so restrictive
It got a little beat up pulling it out
Next i cut out 2 7in by 16in squares of 20 gauge perforated metal. The baffles need to be 2in in diameter. Well circumference equals 2*pi*r or d*pi... 2*3.14 = 6.28 and about 3/4 of an inch left over for overlap.
Next i rolled the steel around a 2in pipe. Its pretty hard but persuasion with a rubber mallet works well.
To keep its form i used galvanized safety wire.
This is completely optional. I like loud exhausts so i did it. The more area of perfoated steel left open the quieter the bike will be. The more area covered the louder it will be. I covered roughly 8in with aluminum tape found at any ACE or Home Depot in the heating and cooling area.
Next i cut the end of the pipe to match the angle of the stock exhaust covers
This now is a goof oportunity to use a high temp paint on your cans if you want them black. Wash them off well and paint!
Next your going to need 2 packs of 4 stroke muffler packing found at Cycle Gear. I cut two 1 in strips and two 2 in strips and used the rest as the wrapping. Because the exhaust is an oval shape i put the 1 in strips on the sides. I then rolled the large piece over them to get the oval shape. Then i took the 2in strips and put them on the sides. I then took safetly wire and wraped it all together so it wouldn't fall apart when putting them into the stock cans.
Next slide your new baffles into the stock cans. Make sure they line up with the inlet of the can and the tip lines up with the outlet. Now slip the stock end cap back on. Now use 3/16 aluminum rivets to put it back together. Once together mount it mack on the bike
Repeat with the second can and you will be done. This is a pretty lengthly process and there are many ways to make your own baffles, so do what you want. Just know that the baffle must me 2in in diameter.
Now what do you think will flow better?
Something restrictive like this:
Or something free flowing like this:
Heres some before and after video..
Before with gutted cats..
After with race baffles and gutted cats..
Again this is a cost effective mod that allows you to save hundreds of dollars on after market exhausts for 04+ R1's. The is exactly the same design that two brothers, Yosh, and the companies use. Its just a free flowing exhaust!
