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wedrivezs

'05 WR450 inner baffle removal

15 posts in this topic

Bro-in law just got his new leftover '05. I've got a '04 that's been jet'd FMF 'd and airbox'd.

We did the grey wire, airbox, and outer baffle mod. I did see that I could take my die grinder and grind out the spot welds holding the inner baffle in.

1) would it be worth it to cut out the inner baffle and still leave our modified outer baffle in?

2) or should we just cut out the inner baffle, and totally blow out a big hole in the outer baffle plate?

3) how wicked loud is this going to be? My FMF is deafining :thumbsup:

I bought my bike this way, so I have no clue what the pipe did for the performance....

BTW, if I lived in CA I'd have a '85 CR500 built to the max, this emissions crap is for the birds!!!!!!!!! You boys in Cali have catalytic converters on your lawnmowers yet??? It's got to be up and coming in the legislature there :thumbsup:

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Bro-in law just got his new leftover '05. I've got a '04 that's been jet'd FMF 'd and airbox'd.

We did the grey wire, airbox, and outer baffle mod. I did see that I could take my die grinder and grind out the spot welds holding the inner baffle in.

Actuallly drilling them out is alot cleaner.

1) would it be worth it to cut out the inner baffle and still leave our modified outer baffle in?

Don't run a baffle at all. Leave the spark arrestor in there and run it without a baffle. Its still going to be quieter than your FMF (I am assuming you have the PC 4) It'll be about as loud as a FMF Q2 on this bike...around 98.5 db

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Buy a PMB insert if you are going to keep the stock muffler. Don't worry, the disease called Kalifornia Fever is working its way to your state. :thumbsup::thumbsup:

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i am assuming that we're talking about the baffle with the two different sized pipes in it (after the spark arrestor plate has been removed)? - I actually got a screwdriver, sharpened it on a grinding wheel and carefully 'punched' around the perimeter of the offending baffle (like a can opener) to remove it and not only does it look great, it also sounds (and performs) better. Then i can re-install the spark arrestor plate (and spark arrestor) if i need to do club rides.

Keep in mind that this will cause your bike to run somewhat leaner and re-jetting it is a must ...

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Your from South Da where!!

Rapid City. We have no annual smog check. So to keep us heading towards extinction, I've removed that cats from my '04 powerstroke, my '79 ford(s), and now I have removed all emissions BS from my bike. OH YEAH, MY 2000 ZX-12R HAS NO CAT ANYMORE EITHER :thumbsup:

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That should be a sticky at the top of this forum........

The front baffle is the one I'm referring to. There is four spot welds at 11, 2, 5, and 7 o'clock. Can I grind them out with a die grinder/cut off wheel and yank that thing out or do you cut cut it out with a long chisel? So far the chisel/screwdriver method seems to be the choice of champions.

I'll plan on enlargeing the diameter tubing that dumps the exhaust out the cover. Is that thing stainless? I hope so, I can't weld titanium......

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I had a question about this subject and figured it would be better to not start a new thread. I removed the first baffle with the two little pipes in it and welded a new tip that fits just around the end cap. The bike sounds way better then it did stock. I feel like I lost some bottom end and didn't gain anything in the top end? Is that normal to lose power? I have done all the other free mods and jetted the bike with the ais removal kit. One thing I did different though was put the clip on the needle back to stock because I was getting about 17 miles before I would hit reserve when I put it to the recommended position now I'm getting about 34 miles before I hit reserve which I still think isn't very good. Any ideas on what I should do?

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dang bosco something doesn't sound right.

I can ride 45 miles without hitting reserve :thumbsup:

Was it real noticeable the loss of bottom end? Apparently you lose a huge amount of backpressure.

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That should be a sticky at the top of this forum........

The front baffle is the one I'm referring to. There is four spot welds at 11, 2, 5, and 7 o'clock. Can I grind them out with a die grinder/cut off wheel and yank that thing out or do you cut cut it out with a long chisel? So far the chisel/screwdriver method seems to be the choice of champions.

I'll plan on enlargeing the diameter tubing that dumps the exhaust out the cover. Is that thing stainless? I hope so, I can't weld titanium......

Hi Wedrivezs,

here is my old post with the pic of the whole stuff removed from the muffler

http://www.thumpertalk.com/forum/showthread.php?t=348969

BTW the long chisel is the best tool to remove the baffle. Good luck :thumbsup:

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Is that thing stainless? I hope so, I can't weld titanium......

Hi Wedrivezs, that thing isn't titanium for sure cause titanium is expensive. It's stainless steel (acid resistant) :thumbsup:

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I noticed quite a loss in bottom end not worth it in my opinion because that is where I like the power. It was hard to tell if it gained any in the top the best way I could figured to measure it was to try some 4th gear wheelies. I have to kinda pump the forks to get it to do them in 4th and it still felt the same :thumbsup: . I just have a stock 06 gas tank is that smaller than the other years? I know the older one's had pretty big looking ones.

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What size tubing did everyone use for the snout?

pretty sad I can't remember, but I think I used 1 1/4 16 ga. steel. Looks like I should have went 1 3/4 and modified the cap.

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