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Tracy Koerner (& his one desire!)




This is a CHENILLE patch Tracy had made. Looks good, huh? How to drill out your pipes!
	1. Drill out the 3 "pimples" (the 3 small raised areas) on the baffle plate. Use an 8mm bit. You only need to drill far enough to "break" the weld.
	2. You have to drill COMPLETELY around the very edge of the baffle, it's welded to the tailpipe (as close to the edge as possible). Probably about fifteen - 10mm holes. Then take tin snips and cut between the drill spots. Then you have to bend the edges of the baffle with a screwdriver or pliers or whatever! (backward or forward, whatever it takes to get the damn thing out!!) and pull the baffle out. It takes some work to get it out because of angle the baffle is made.
	3. With a stone grinder bit on the end of the drill, smooth out the remaining rough spots on the tailpipe.
	4. It should sound pretty good now.
	5. BUT, if you want an even BETTER sound - you will need to buy a 300-400mm extension ($4-5USD). Inside the tailpipe there are TWO plates. The 1st one has a large hole in the center and 2 smaller holes on the side. DO NOT TOUCH THIS ONE!! With the extension and a CONE SHAPED stone grinding bit, slide it through the 1st large hole. At the second plate, there is a small hole about 15mm wide. It is slightly up and to the left of a larger hole (30mm). READY?, Start grinding on the smaller hole until it is about 20mm or you like the sound. DONE!!!!
	Voila, you have a great sounding bike (at least at idle). It does have a little more sound throught the gears but nothing like a straight pipe.
The "kit" I got from the guy in Sweden was only two small cones that fit inside the tailpipe to increase the backpressure. They really were not anything special. I would also suggest spraying the inside of the tailpipe with some black high temperature paint to revent any rusting.

Several shops around here carry these. They are around $20-$22 plus tax. They are the heavy/thick leather. Finished with a shine on one side and the unfinished suede on the other. Not the thin cheap crap. 16" long (the longest I have found, they also make a 10"). They make them for the levers and for the handles. You really can only get the one for the levers because the 1500 has that finished chrome cap on the end of the handles (you don't want to cover chrome! It helps to grip the clutch/brake better and I think the one for the handles are made for open ended handles - no caps). J.C. Whitney sells this kind but theirs has metal reinforced eyelet lace holes (mine do not). Whether it is the heavy finished kind I am not sure. (grip covers #01AA0820P $18, lever covers #01AA0821Y $15 or $28 for both sets #01AA0822W Tel.312-431-6102) They also sell the one in the 3rd picture that is 16" at one end and angles in length to 8" (those are $8.50 #01AA1134N).

It helps ALOT. I hand Bi-lateral (both wrists) Carpal-Tunnel Syndrome when I was 20. It still hurts once in a while, especially after I have been riding a while. But this helps reduce alot of the stress and tension on my wrists. It is a little weird at first because you have to hold the handle a little different, you can't get your hand entirely around the grip) but it's worth it...

Drill out the 3 "pimples" (the 3 small raised areas) on the baffle plate. Use an 8mm bit. You only need to drill far enough to "break" the weld.
Pop the thin (black) back plate off with a screwdriver and pair of pliers.
Now with a 8-10mm drill bit, drill several holes (15-20?) completely through the remaining backplates. Drill all the way around the around the outer edge of the muffler casing as close to the edge as possible.
Now, take a pair of tin snips (metal cutters, or whatever you call them) and cut the portions between the drilled spots. The interior baffle should now be loose.
Now remove the baffle from the tailpipe. You will have to bend the flange on the baffle so that it slides out. This probably takes the longest.
Once the baffle is out use a grinding bit in the drill and smooth out the inner edge of the tailpipe.
Use a 300mm extension in the drill with a cone shaped stone grinding bit. Inside the pipe (about 200mm) there is a plate with 3 holes in it. DO NOT TOUCH THIS ONE!! Reach through it with the extension to the 2nd plate. It has one large hole (30mm) and a small hole(15mm) place the grinding bit in the smaller hole and grind it out until it is about 20mm or it sounds good.

Start the bike occasionally and check for sound during the grinding process.
VOILA!!! FINISHED!!!!