[Archie 62]

It got me upset that this job had me beat, so I got on this site and read two things that helped me get the job done,one was ManHandle it, and the other was get a Bigger hammer, lol that worked for me, also that these baffles will not come out after you loosing them because of the two tangs on each side of baffle, you have to twist the baffle inside,then it will come out easier, I manhandled it,and bigger hammer worked for me

 

[Archie 62]

 

[scootersage]

The 01 road star has the ends drilled out. 5 or 6 holes drilled around the center. Bike is all stock with ais so didn't want to much opened up. It sounds great not to loud but you can hear it when riding.
Don't they just use a hole saw to take the baffle out.

 

[random_guy]

The 01 road star has the ends drilled out. 5 or 6 holes drilled around the center. Bike is all stock with ais so didn't want to much opened up. It sounds great not to loud but you can hear it when riding.
Don't they just use a hole saw to take the baffle out.

Sounds like what I’m trying to do with my Warrior. Only problem is that the pipe is welded to an interior bulkhead…

Now I’m trying to figure out how to break those welds so I can cut out the bulkhead with a hole saw and clean up the holes’ mess.

 

[scootersage]

I have seen a youtube video where they took a hole saw and welded it to a pipe and sawed it all the way to the end.

 

[random_guy]

I've seriously considered trying to do something like that... Right now, I'm thinking about putting a small cutting blade at the end of a LONG arbor and using a pipe to guide where it's cutting to make some room, then using a hole saw to finish the job of removing the bulk of the bulkhead. I just don't have much time to tinker with things like this so what could be a long weekend project is taking months and months. :/

 

[prien6207]

Why?

 

[prien6207]

Why bother, aren’t aftermarket pipes readily available?

 

[random_guy]

Sorry for hijacking your thread, @Archie 62.

Yes, aftermarket pipes are available, but not all that readily. The Warrior has been out of production since 2009 in the states and it wasn't all that popular when it was being produced so the aftermarket scene never really blew up. I actually have three different exhausts for my bike, but am hoping to get a different sound than what these produce.

• Stock = really quiet and muffled at idle and acceleration
• Speedstar = not terribly loud at idle but super loud on acceleration
• Rinehart = fairly loud at idle and fairly loud on acceleration

I'm hoping to get my modified stock exhaust to be not terribly loud at idle and deep muffled on acceleration. Also, here's a video clip for someone that has cleared out everything inside but I'm trying to not require welding as part of my modification process.

 

[random_guy]

I JUST found a video that is EXACTLY what I am working on. Hoping to streamline some of these steps, but this is what I'm in the middle of right now.

 

[random_guy]

Here's how those end up.

 

[random_guy]

Rinehart exhaust clip for comparison