Yamaha V-Star XVS 650 “No Cut Gut” – Stock Exhaust Modification



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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