XS 650 Low Restriction Exhaust Baffles

Three allen bolts mount the big baffle tube to the billet aluminum end cap, (top baffle) with the stainless steel turn down outlet. Removing the three allens lets you separate the pieces and remove the turn down outlet, and then it just bolts back together. Results with the above center baffle (its a VHR competition 1 3/4 inch bore baffle for the air cooled Suzuki GS & Kawasaki Z & KZ series 4 into 1 headers) were excellent compared to the stock bottom MAC baffle, but the long, big smooth bore top baffle performance blew it away too. With a 2 into 1 exhaust system design, the pulses help scavenge each other, and make the motors pull harder from low rpm too.

I modifed the above large 2 3/8 inch smooth bore VHR (Vance & Hines Racing) Super Sport "race" core baffle for the late model GSXR's, Ninja's etc. I put it in the mac 2 into 1, (paid $200 for a 79 and the 2 into 1 Mac header was on it) and this stock 1980 motor with 36 VM Mikuni carbs came alive, unreal response, it really breathes freely in and out now. With the mac baffle ( I knocked out the "bottle cap"center piece in the mac baffle) the exhaust system was still choked, and stopped up, roasting the motor and the headpipes. It is super crisp now and really responds, runs cooler with less throttle opening at any speed too, and pulls real hard from idle to redline! Its a little loud when you nail it, but sounds great, it has a deeper tone with the fiberglass packing.

I measured from the end of the tapered end pipe, inside to the billet end cap, then marked that measurement on the outside and drilled and tapped a new hole into the billet cap, to retain it in the pipe.

The big front OD of the long smooth 2 3/8" perforated core blends snug into the walls of the front tapered section now, both primary pipe pulses go directly through the big smooth baffle core without running into the non laminar tiny stock baffle front flat disc.

Whatever system you use, if you get it flowing less restricted, with a baffled single system, dual mufflers etc, you definitely won't be disappointed with the improved throttle response, smoother running and increased performance.

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