2002 - 2009 (and now 2014+, kind of) Honda VFR 800 Interceptor Modification Page

Site Owner:  Sean Murphy

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Modification Links:*

Lowering Your VFR800 or How to Make Your Legs Feel Longer

Adding a Car Alarm or Put the Ignition Punch Down, Step Away From the Bike, and Nobody Gets Hurt

Adding Hazard Lights or Sir, The Lights Are Blinking and Flashing... Flashing and Blinking

Wiring Up Rear Turn Signals to Act as Marker Lights (Like the Front) or For the Love of God Don't Hit Me

Changing Your Side Markers or I Don't Want to Ride a Huffy

Changing Your Horn or Land Yacht... Coming Through

Securing Your Jackets and Non D-Ring Helmets or Is It Safe?  Is It Safe?!?

Invisible and Removable Tank Protection or Scratches... We Don't Need No Stinking Scratches, Man

Adding a Vista Cruise Throttle Lock or I Feel the Need... The Need for Steady Speed

PAIR Valve, Variable Air Intake Valve and Snorkel or I Don't Want to Hear It... The EPA's Energy Star Program Approved a Gas Powered Alarm Clock...

Exhaust Baffle Removal or Can You Hear Me Now?

Make your VFR a True Solo Seat or How Often Do You Ride Two Up?

Resources... We Have Resources?

My VFR's Specifications or Do You Really Care at This Point???

*Note:  The information on this page is not intended as instructional.  I am not a professional mechanic nor do I play one on TV, but I did stay at a Holiday Inn last night.  These modifications can be dangerous and even deadly if improperly implemented.  You should always consult a Honda certified mechanic for all modifications.  I accept no liability for any use or misuse of this site (no good deed goes unpunished).  This fine print brought to you by the Law Offices of Dewey, Cheatem & Howe.     "I'm not even supposed to be here today."  --Dante Hicks, Clerks


Exhaust Baffle Removal


This one is one of the more difficult modification to do without needing a welder.  Now if you have a welder and can weld, this should be a snap.  First let me say I did not remove the catalytic converter.  You need a welder to properly remove the cat to reduce back pressure fully, although this will help when combined with the VAIV, PAIR, and Snorkel removal in the above modification.  The pictures during the build were lost, so I can just show you the after pictures.  You will need the following tools:  Dremel with flex shaft attachment, Dremel reinforced cut-off wheels, two 16" needle nose pliers, needle nose pliers, razor cutter, Dremel sanding discs and a metal file. 

Start by loosening the bolts where the exhaust meets the cat and remove your rear fairing.  Then remove the hanger bolts for the exhaust and lower it onto the rear tire.  Remove the shields and make sure you have the rubber tab inserts and the two rubber hex spacers (small items look around).  You can then remove the exhaust (it can be done without removing the rear tire, just wiggle it). 

Now the fun begins...  Cut along the weld seam for the end cap but cut across at a 45° angle where the end cap shield nut support is located so you can reattach your end cap shield.  See first picture, bottom exhaust outlet, you can see the only part of the end cap left.  Once that is done, use the cut-off wheel to go around the baffle following the holes in a row about 2" at a time.  You will then need to use the pliers to fold in the baffle to get it past the end cap portion you did not cut off for the end cap shield retaining nut.  (Now if you can weld, just cut the cap off and pull the whole thing out and weld the cap back on and done.)  Keep cutting the baffle like this all the way to the end using the Dremel flex shaft and extended needle nose pliers as you get deeper.  Now reaseble in reverse. 

The exhaust sounds like a ALMS car rumble from the V-4, but not as loud as a Harley.  Love it!

Total Time:   4 Hours
Total Cost:  $0.00 


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