2007 Yamaha R1 Racing Baffles Installation Directions
Steps for disassembing, packing and reassembing of 2007Yamaha R1 slip-ons: Read instructions fully before starting. Give yourself time to complete; you don’t want to damage anything on your bike. We do not guarantee proper installation. Install at your own risk.
Tools needed for completion:
- 3/16 Titanium drill bit (make it 2 just in case you break one)
- Corded drill (most cordless do not provide enough power)
- Rivet gun
- Hammer, preferably a rubber mallet
- Safety glasses
- Dremel w/ cutting bit or grinder
- Screw driver
- Misc. socket sizes
- Allen Wrenches
Tools needed for completion:
- 3/16 Titanium drill bit (make it 2 just incase you break one)
- Corded drill (most cordless do not provide enough power)
- Rivet gun
- Hammer, preferably a rubber mallet
- Safety glasses
- Dremel w/ cutting bit or grinder
- Screw drive
- Misc. socket sizes
- Allen Wrenches
1. Remove slip-ons from bike and place on bench with towel or mat to prevent scratches. A vise is not needed (Seat and rear side panels must be removed to take off mufflers. Refer to owners manual for proper instructions if need).
2. Remove heat shields from slip-ons.
3. Using sharp 3/16" bit, drill out heads of 4 rivets on tail end of can of both mufflers and push them through using awl, punch, or screwdriver then remove cap using hands.
*Before removing black cap, you can use a pencil to make a mark around the cap to ensure you don’t cut to far down during the next step.
4. Remove black exhaust cover from end of muffler.
5. Using a grinder or Dremel, cut the 4 welds on each can. Be sure to cut out entire weld without cutting past your line.
Others have used a drill bit to drill out the weld marks, this is up to you which method to use.
6. Having a friend hold the muffler as seen in photo below, hit the tip of the OEM baffle at an angle to knock out of can. Be sure not to hit the muffler can.
7. Use your hands to pull out the rest of the baffle.
8. Unwrap factory packing from baffle. You may need to use a razor blade to help.
9. Lay out both parts of OEM packing and Vance and Hines.
10. Wrap the OEM copper mesh around the center of the race baffle.
11. Next use OEM fiber glass packing and roll at an angle as seen in photo below to cover entire baffle.
12. Use Teflon tape to hold packing material in place.
13. Trim packing with scissors to match shape of race baffle.
14. Now cover entire baffle with Vance and Hines packing.
Material that looks like nylon is really fiberglass, this goes on the outside.
15. Use Teflon tape to hold packing in place. Wrap around several times to ensure the packing stays put.
16. Now trim packing with scissor to match the shape of the race baffle.
17. Install race baffle into can. Hold packing material in place when inserting. Make sure the angle goes towards the bottom of the can.
18. Install end cap and use fingers to align core with cap. Make sure there is no packing material hanging off the angled end, trim with scissor if necessary.
19. Using supplied rivets and your rivet gun secure cap.
*When using the rivet gun, do not use fast, hard squeezes on the trigger. Instead make short, smooth squeezes to insure a tight closure. With the rivet gun still connected to the rivet, move the rivet gun side to side to verify that the rivet is tightly in place before the final squeeze.
20. Install slip-ons on bike and remember that they may smoke and/or smell until they have gotten hot a couple of times.
*Warning, do not stand behind bike when you start it for the first time after baffles are installed. Small pieces of fiberglass packing material will be ejected.