My exhaust pipe has something rattling around inside it. Sounds like a pretty stout chunk of steel and I'm thinking it's some kind of baffle or bracket that's broke loose. It's eating at me and I need to get it out so I can remove, or repair it if it turns out to be important. Whatever it is it's for sure not doing any good floating around loose in there. No way to get it out without cutting the pipe open. I'd like to cut the hole as small as possible and right over the area it needs to be to make it easier to weld back in place if necessary. I'm guessing one or more of you guys have cut these open at some time and if so I'd love to see a pic of internals if anyone happens to have one.

Forum member Meiss could make you a sleeper pipe as he cuts them open to change the internal flow. He’d be in there anyway. I’m sure the noise is a piece of baffling. Could plug up the outlet if not removed plus the rattling around would bug me too.

Yup- contact Dave. He may even have posted up some photos of pipes he has modified, kind of "before and after" pics.

I'm going to use the pipe I have . No sleeper needed for my purposes, it ran fine before, (suited me anyway) so just need to get that baffle out of there or welded back in place. I think I'll go over after while and poke around in there with a wire, might be able to feel out whatever's left of original weld point. Worst case I'll just have to cut the hole a little bigger than necessary.
Edit, just sent Dave a message.

I have some photos of the inside of the pipe and how to make a sleeper pipe in my thread here
www.yamaha-enduros.com/index.php/forums/...crapper-bike?start=0

My stock pipe had the same problem. Internal baffle was broken more or less in half and was rattling around inside. Held just right it was visible through the outlet end. I cut open the back end of the pipe on the inside, opposite where the heat shield screws on. Made about a two inch square flap, removed the chunk and welded the flap back closed. Made no difference other than peace of mind.

If you don't have a welder and you'll have to pay for it either way, a sleeper pipe makes a lot of sense. More power never hurts.

Thank you akara! I knew I'd seen some pics like that somewhere awhile back but my search skills suck and I couldn't find it back. That's exactly what I needed. I think it must be the big bracket that you took out. That must be what I'm hearing in there. I'll look for the rivet that you drilled out. I should be able to cut out a pretty small section right there and be able to either get it out or weld it right back in. Looks to be very close to the end of the pipe.
What are your thoughts on whether I should just take it out completely or remove it? I'm thinking I'll put it back in there where it was but don't think it'll make a noticable difference either way.

Thanks turbo, I have a welder so I'll just stick a thin wheel on my little angle grinder and cut a little square out, fix or remove the baffle plate and weld it back shut. Pipe seems pretty solid so should be easy to weld even with my antique stick welder.

Got it out. Looks like it must have been a support bracket for a tube that must have run through there at one time but there's no trace of it now other than the bracket itself. I can see where it was welded along the bottom edge and from it's shape I can figure out which way it sat in there so I know where to put it if I decide to put it back in. Not sure what it's original purpose was or if it'd do any good to put it back in there now so have to mull on that for awhile. Fingers got too cold to work so back in the house to warm up while I think it over. Thanks for the info guys.

Thanks for sharing pictures of what you found inside!