How to Drill a Harley Muffler

Harley-Davidson motorcycles are known for their dependability, quality parts and workmanship, powerful engines and loud exhausts. However, most Harleys don't come standard with a loud, deep sounding exhaust. Oftentimes this is an aftermarket modification made by the owner to boost their noticeability on the road, making for a safer, less worrisome ride. Be noticed on your Harley by drilling out the stock baffles of your muffler.

Difficulty:

Moderate

Instructions

Things You'll Need

• Bike lift
• Metal cutting drill bit
• Hand-held drill
• Vise
• Shop rags
• Standard wrench set
• Rubber mallet

1. • 1

     Consult your owner's manual to determine where and how the exhaust pipes are held onto your specific model of Harley then set it on its kickstand or a motorcycle work lift.

   • 2

     Use the appropriate-sized wrenches to remove the exhaust system from the motorcycle. Be careful not to misplace any of the bolts or metal gaskets as they will be used to reattach the exhaust later.

   • 3

     Place the exhaust in a vise covered by shop rags or towels. Do not over-tighten the vise to avoid damaging the chrome finish on the pipes.

   • 4

     Attach an extension and a metal cutting drill bit (between 1/2 and 3/8 inch) to your hand-held drill. Insert the tip of the drill into the end of the muffler and drill through the first two baffles. Try to center the holes in the exhaust to prevent "whistling" when the exhaust is placed back on the bike.

   • 5

     Tap the mufflers with a rubber mallet or a fist to remove any remaining bits of metal from the drilled baffles. Reattach the exhaust to the bike. Make sure to tighten all bolts to the torque specifications found in your owner's manual or maintenance guide.

   • 6

     Fire up the bike and listen to the exhaust. It should be much louder and sound slightly deeper in tone. Take a quick test ride to show off your new, loud pipes.