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Discussion Starter #1
Could someone steer me to some instructions on removing the baffles from the stock mufflers?

What's the end result of doing this?

Do I need to disconnect the 02?

Any comments on removing the CATs plus disconnecting the 02s plus removing the baffles would be appreciated. I have read a lot of info and even started a thread on just the CATs removal but am mostly interested in this thread about doing all 3 things and what the end results would be.
 

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There are threads covering this, one having the title Cheap Mods, or something like that.
You'll need a 1-1/8" hole saw and an extension long enough for it to reach the baffle. Mine required a 1/4" rod. Do everything to make sure the saw does not get left in the pipe.:( I filed a flat in the rod for the set screw and used blue loc-tite. The baffle is very thin and cuts easily.
As for the sound (I was concerned about that too) your neighbors won't know you are leaving, but she'll bark when you twist 'er on. There's a nice purr when cruising along.
O2s won't effect it, but I removed mine for richer and cooler running.
 

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Discussion Starter #3
There are threads covering this, one having the title Cheap Mods, or something like that.
You'll need a 1-1/8" hole saw and an extension long enough for it to reach the baffle. Mine required a 1/4" rod. Do everything to make sure the saw does not get left in the pipe.:( I filed a flat in the rod for the set screw and used blue loc-tite. The baffle is very thin and cuts easily.
As for the sound (I was concerned about that too) your neighbors won't know you are leaving, but she'll bark when you twist 'er on. There's a nice purr when cruising along.
O2s won't effect it, but I removed mine for richer and cooler running.
Thanks M8T ... and I believe I have the appropriate tools since I drilled out the baffles on my Road King mufflers which I installed on my '06 Venture.
 

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Discussion Starter #4
Found this on another forum (slightly edited)

1. Remove hard bags.

2. Where the slip on (muffler) meeets the header, loosen the clamp for the slip on and then loosen the clamp for the heat shield. The heat shield stays on the slip on via two other permanant clamps.

3. Remove exhaust tip. There are three bolts.

4. Remove two bolts that hold the slip on to the frame.

5. Now be careful and manipulate the slip on by wiggling it slightly and pulling to the rear of the bike. Make sure the bike is on a stable platform. If you have a rubber mallot you can lightly tap the bag mounts to help slide it off.

7. Get two 12" drill extensions and a 1 1/8" METAL hole saw. DO NOT GO BIGGER THAN 1 1/8" IT WILL NOT FIT. The baffle from the inlet side is about 16" in the pipe. Make sure the drill extensions and the hole saw are secure so you don't leave one in the pipe. It would be difficult to get it out!

8. Stand the slip on on the outlet end on a block of wood so you don't bend the tip.You will see that the slip on is slightly offset on the inlet side so carefully insert the hole saw between the three baffles and center it up. Start slowly because the hole saw can bite hard and may twist the pipe out of your hand! You will feel it when it finally punches through. the metal is not that thick.

9. Remove the hole saw and turn the slip on upside down and let the slug drop out. Make sure you didn't leave any thing in there.

10. Now reverse the steps and start on the other one.

You may need to put the Stage 1 map on it and install a K&N or some other high-flow filter.
 
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