Yamaha V-Star XVS 650 “No Cut Gut” – Stock Exhaust Modification
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Feby
Stage 1 – Remove Cone and 1st Baffle
Plate • Start by cutting out the end cone using the 1” hole saw. The
black cone is only welded around the small exhaust pipe (final exhaust
pipe). There are one or two spot welds you should see and that’s all
that holds the cone on. If you don’t have a hole saw, you can use a
Dremel tool with a cutoff wheel or the chisel to remove the welds. Once
the cone is off, you should see the first baffle plate. • Drill a bunch
of holes around the outer edge of the baffle plate using the ¼” drill
bit. • Use your standard chisel to finishing knocking out the plate. •
Wiggle the final exhaust pipe around until it breaks lose. It will drop
down in the muffler, but you won’t be able to pull it out until you
remove the 2nd baffle plate. Remove 2nd Baffle Plate • Use the longer
chisel to knock out the second baffle plate along with the final exhaust
pipe. • Now you’re left with the third baffle plate and the inner
exhaust pipe. Remove 3rd Baffle Plate and Inner Exhaust Pipe This can be
removed two different ways and both take about the same amount of time.
One thing to keep in mind is when you look down at the third baffle you
will see how it steps up around the outer edge. Cut it below and inside
this step. Method 1 • You can buy an extension for your drill and
drill a bunch of holes around this plate. • Then use the 24″ long chisel
to knock out the baffle plate and the inner pipe. Method 2 • You can
skip the drill and just use the chisel to knock out the baffle plate and
inner pipe.
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