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Hello, I am sure this has been covered and I found some old discussions but did not get my question answered. I am thinking of taking out the baffles on my 88 Kawasaki kz1000 police. Is it as easy as just drilling with a hole saw and pulling out the baffle? Thanks for any help

The baffles are probably welded. I don't know about the KZ1000P, but the 81 650-CSR mufflers have an end plate with a tube welded to it, then another plate in front of that which you can see by shining a flashlight inside the muffler tip, then further forward theres another baffle tube (shown in pic).. and maybe some other baffling as well. Some manuals show a cross-sectional drawing of the mufflers.


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If you want it louder you can use a long drill bit and open the end plate. If you pull them out you will lose top end power. You need back pressure to make ponies.
Steve

I'm not sure I understand what you mean by opening the end plate.

Not that I recommend modifying the exhaust as the noise is going to be annoying, but you could try drilling a series of holes into the muffler end caps. The plates forward of the end caps probably have a series of holes w short tubes, so if the end caps are drilled, that should open up the exhaust. I bought a 750E muffler system that had been drilled, but I plugged the holes.


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The last factory exhaust I dissected was a Kz400, and it was like Martin is describing. There would have been no way to "pull out the baffle" as the divider plates and tubes were all welded in. We had to cut the muffler apart to see the inside.

If the original exhaust is in good condition, I would recommend getting an aftermarket exhaust to experiment with. If the old system is rusty and the mufflers are pitted, you might try to cut them off and weld on mufflers that have removable baflles. (That is, assuming the factory exhaust is like the other factory exhausts where the baffles are not removable.)

The muffler in question might be different, but here's how the KZ650 muffler is made. Those partition walls are welded in place, so I see no way to remove a baffle without wrecking the muffler. Also, there are no removable end caps. The ends of the mufflers are formed and welded into one piece (second image below). Ed

Unfortunately my mufflers don't look like that.

Yeah, that's what mine look like. May end up getting good some aftermarket. Don't want it annoying loud, just a bit more throaty.