Triumphrat

Scrambler Muffler - Rear Baffle Removal


Over this winter I've enjoyed reading numerous member posts on opening up stock mufflers with a "Bafflectomy". The huge thread
started by kdlutes (with pictures) gave me confidence to go after my Scrambler mufflers. I'm not into loud exhaust, but wanted a deeper
sound that is a little closer to the classic Triumph sound. My hope is that this post will give others looking for a small volume boost the
confidence to take on their own baffles. I'm happy with the results for about 3 hours work. I strongly suggest pulling the mufflers and
mounting them in a bench vise. It is simple to remove and install the mufflers and the force needed to tear the baffle tabs free of the
front plate is considerable. I haven't made any intake or jetting changes so far... will evaluate with more miles

Tools Needed:
1 and 1/8 inch hole saw (good quality to cut metal)
Portable drill
Bench vise
(2) 90 degree L brackets to support muffler in vise
Big 12” long screwdriver or bar
Vise grips
Needle nose pliers
Drift
Hand tools to remove exhaust from bike
Rat tail and small bastard files
Flashlight
Confidence
Patience
Cold beverage of choice

Steps:
Remove rear muffler guards (4 screws - #4 allen wrench)

Remove (2) rear muffler support bolts from backside of hanger bracket - top muffler. Loosen top muffler clamp to header pipe (10mm socket). Remove top muffler
by twisting and sliding to rear


Attached L brackets to muffler mounts using bracket screw just removed


Place muffler brackets in bench vise to support muffler for bafflectomy


Place 1 and 1/8 in. hole saw in drill. Take aim at your target.
Drill with very light pressure and fast drill speed – it will take
one or two minutes to cut thru the rear of the baffle. Be patient with light pressure on the drill... and stop when the hole saw breaks thru the rear flange


Some have used a socket over the loose baffle to drive it forward to break it free from the front baffle plate. When I did this the
front plate came free of the inside of the muffler. Insert long screwdriver and start twisting and bending the loose baffle


Work the baffle out with screw driver and pliers / vise grips

When you have the rear baffle out 1 inch or so, cut the wire holding
The fiberglass wrap and pull out the packing using needle nose pliers

Keep twisting and bending the rear baffle to break it free from the front baffle plate (use flashlight to see progress of breaking the flange tabs loose).
This may take a while. If you get impatient, walk away and relax for a while... you will get it done


File down rough hole saw cut in rear of muffler with round and bastard files. Repeat same procedure for second muffler. Here are the removed baffles


Reinstall mufflers and heat shields. Go Ride!
(video and sound file link below)

http://s672.photobucket.com/albums/v...t=DSC_0007.flv