How to Remove Baffles From Yamaha Virago Motorcycle Exhaust Pipes

The Yamaha Virago was the first of the Japanese V-Twins inspired by, or marketed as an homage to, American Harley-Davidsons. The Virago is no longer manufactured. It was replaced by the Star. During production, there were at least 10 different Viragos with engine displacements from 125 cubic centimetres to 1100 CCs. Your bike may differ from the Virago 1100 modification described here. Before you start cutting you should know that both complete aftermarket exhaust systems and slip-on mufflers are widely available for most Viragos. If you still want to keep your present mufflers without the baffles you need to remove both the end cap and the baffle. It is a brief, brutal job.

Loosen the slip joint clamps where the front and rear exhaust pipes connect to the mufflers with a socket wrench and socket.

Remove the muffler box mounting bolt in front of the right passenger foot peg with a socket and socket wrench. Remove the right passenger foot rest assembly with a socket wrench and socket.

Spray penetrating oil on the muffler exhaust pipe joint. Tap the mufflers with a rubber mallet.

Pull both mufflers off the exhaust pipes. Set the mufflers on a stable work surface. Work on one muffler at a time.

Use a Dremel or equivalent rotary tool to cut the weld in each muffler that holds the end cap inside the muffler. Remove the end caps with vice grip pliers.

Drill out the baffle plate in each muffler with a 1 3/4-inch hole saw chucked to an electric drill. Remove the baffle plates with vice grip pliers.

Turn each muffler, one at a time, end-down on a sturdy work surface. Insert a 2-foot length of 1-by-2-inch wooden furring strip into the open end of each muffler.

Beat the end of the furring strip with a rubber mallet until you drive the baffle out of each muffler.