I have been hunting a rattle in my stock Vulcan 800 exhaust and was hoping someone else has had the same problem and can offer a solution other than replacing the pipe. It started after about 10k miles and shows up at certain revs and loads but is very loud and annoying. It is not the shields or any loose hardware. I think I have isolated it to the front pipe (using a long screwdriver up to my ear like a stethoscope) . It seems like a weld broke loose in the baffles maybe. Any suggestions?

 

welcome to KF! have you tried a search in the vulcan section? you might find it in there.

 

Yes I did. I did not find anything.

 

and you are sure it is the exhaust and not possible engine noise/wear/adjustments or loose engine mounts?

 

Those were my first thoughts. I checked every mount and bolt I could find. It is a very distinctively tinny sound and sounds a lot like it might be a broken weld on a baffle. I believe I can pinpoint it to where the header pipe enters joins the muffler, but I could be misleading myself. I can make it resonate just by playing with the throttle while in neutral, but it is mist pronounced when accelerating and shifting gears (when the rpms are dropping between shifts).
Does anyone know how to get the baffles out without cutting the thing apart?

 

Interesting, but I do not know how to take that muffler apart.