| Photo 1: Stock Exhaust Airflow {cross section diagrams}
As the exhaust gases are forced out the headpipe, they are directed into the outer portion of the muffler body by the forward baffle. The gases then flow through a fiberglass packing (yellow in the diagram), and are again redirected out the tail pipe via the rear baffle. |
Photos 1 & 2 Stock system removal
First step of course is the removal of teh stock system. The two mufflers are attached by an equalizer section behind the two mufflers, so the entire system is removed as a whole. Remove the bolts on the frame bracket, and then remove the acorn nuts holding the headpipes to the engine. You'll also have to remove the stock frame bracket for the pipes as most aftermarket systems have their own bracket. See the "Engine/Frame" page for a detailed fastener location of the stock exhaust system. |
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Photo 2: Drilling the Baffles
Using a 12" long 3/8" drill bit, run the drill through the center of the rear baffle, once punctured continue into the forward baffle. You can "tune" the muffler's sound by drilling additional holes, most folks are content with three to four holes. |
Photos 3 & 4 Fitting the new pipes to the motor and frame
(Editor's note: pics 3 & 4 were printed in reverse order...4 should be first)
First off you'll need to remove the old exhaust gaskets, use a thin flathead screwdriver and gently tap them loose. Insert the new crush gaskets in their respective ports. ITEM: the VLX uses two different sized gaskets, the front is slightly larger than the rear...so don't let the parts guy sell you a matching pair as is often the mistake of assumption on their behalf when looking up the part numbers. After the new gaskets are inserted, add the new frame bracket, followed by lining up/inserting the new pipes one at a time.
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Photo 3: Drilled Baffle Exhaust Flow
Here you can see the airflow on the drilled baffles. Similar to the stock airflow except now some of the gases are vented through the baffles while the rest is directed through the fiberglass packing. This mod results in a louder tone while still retaining some back pressure.
Some folks find themselves not quite content with this mod, and will instead take a 1 3/4" hole saw to completely excise the baffles. This makes for a really loud pipe, and is also illegal in many states so make sure you check your local laws before going this route. |
Photos 5 & 6 Tighten it all down
Almost there...line everything up and then tighten everything down. Now you'll be able to sample first hand the new personality of your old bike!
You may want to rejet the carb(s) afterwards for optimum gains with the new exhaust system. See the "Carburetor" page here for details on that procedure.
One other notable item: the procedure above deals with most exhaust systems except the DG Performance systems...DG assembles like the stock system, the two pipes are fitted to the frame bracket first and then the entire assembly is attached to the motorcycle.
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