Picked up my new bike in Feb and have been reading the topics since then. A lot of info on Bonnie's but not too many clear instructions for the Scrambler and so was really worried in case I totally destroy the pipes. Finally picked up the courage on Saturday and here the results. The 2007 Scrammie has the locator type baffle (not tack welded). After cutting with an 1" 1/8 bimetal type hole-saw (about 10 secs) the baffle pushes in quite easily and leaves a lip about 3mm thick that must be ground away. Thats easier said than done and eventually (after about 40mins) I gave up and cut 5mm off the muffler with a cutting blade. The baffles then pull straight out. I was thinking I maybe should have used an 1" 1/4 hole-saw (to leave less of a lip to grind) but this would mean cutting on the raised lip and I'm not too sure I would have been steady enough. Had to take top pipe off also to avoid cutting into indicator. The edges are quite neat although the chrome plating has a couple of tiny flakes around the edge. Will try and trim back another 5mm or so for a perfect cut. All in all though I love the new sound and have saved a bundle of cash. Heres the thing - was thinking I could have used a plumbers pipe cutter for steel pipe and cut off the last 5mm of pipe straight away therefore making it a 5 min job with a perfect cut. Would this work?
No jetting changes. Were so high here in Joburg that I never considered going bigger. No drastic changes but seems to run better - and sounds more like a bike. I would have bought the TORS from new but didnt really want to spend more money. Cruises happily at 140 on the way to work this morning. Im happy for now.
I removed the baffle in my Scrambler almost the same way. However, I used a Dremel with a cut-off wheel to help cut off the flange left after the hole saw.
After I removed the baffle I used 1/2 inch drill bit with extension to drill through the other dividers in the can. You can drill through two of the plates with a extended bit.
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