2024 Aprilia RS 660 Extrema | DB Silencer removal | How to remove Baffle in exhaust

How to remove a 2024 Aprilia RS660 baffle/decibel killer from your Project SC stock exhaust. All you need is a angle grinder, Allen wrench, rivet gun, 3/16 stainless steel rivets flat tip screwdriver and a hammer with a rubber grip or a rubber mallet.
Get the most out of your stock exhaust without the worry of voiding a warranty, throwing any codes on your dash or flashing your comp.
Start out by removing your exhaust tip by taking off the spring. Remove the bolt that's attached to your passenger foot peg. From there you're going to take a 3/16 drill bit and drill out your rivets on the end cap. Once all rivets are removed use a backside of a hammer, screwdriver or anything solid that will fit on the back side of the exhaust to push the decibel killer cone portion out of the end of your exhaust. Once the decibel killer is removed use a grinder or a die grinder to cut just below the weld. Once this step is complete the decimal killer will be freed from your exhaust end cap. Attach the incap back onto exhaust followed by the carbon cap. Install brand new stainless steel 3/16 rivets and mount it back onto the bike.
#aprilia #rs660 #extrema #exhaust #apriliaRS660Extrema #sportbike #motorcycle #dbkikkerremoval #loudpipessavelives #apriliaRS660

[@Saidf430]

I came from the group to check the sound of your Machine and let me tell you that this thing sounds amazing

[@franciscojuanchi6052]

@@Saidf430 thank you, the video doesn't do it justice. The growl is so much deeper now.... Really brought the bike alive... Thanks for watching!!

[@irkdhesa]

I've been wanting to do this for a while and saw several sites that offered "instructions", but none of them were very good and were very basic.
I did this today and the bike sounds so much better and deeper (my opinion). The OEM 2024 Aprilia RS660 Extrema one lacked a little. It's like it make it sound like a racing car exhaust (Don't know how to explain it). Much deeper and a bit louder. I really like it.
I have a Yamaha FJR 1300 ES with dual Two Brothers exhausts that sound amazing. This isn't as loud (only one exhaust), but it's probably close to the Two Brothers if my FJR only had one.
This video at least helped me understand the different steps they were talking about in forums and what to expect once I got it open. However, there are a lot of caveats and I know why people don't really want to do this. I broke 2 drill bits and didn't have an electric rivet gun which made things extremely difficult. I do have a really nice Dremel with metal cutting bits and it make an extremely clean cut to remove that DB killer.
Things to consider
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1) It's not too hard to remove the exhaust once you remove the bolt (on the foot peg) and remove the spring holding it on. I did have to wiggle and use a soft mallet to help me get it off.
2) Stainless steel rivets are used. If you have a hand rivet gun, it's going to be tough. I ended up positioning my exhaust next to a table and used my full body weight just to get the rivets put back in.
3) If you know how to remove rivets, you may have better luck. I learned the hard way as I broke 2 drill bits (3/16"). There is room to punch the "nail" in the rivet down into the exhaust. This will make it easier to drill out. Once you get it down far enough, you can drill and maybe wiggle a little bit side to side until the head of the rivet comes off or loose. Then you can use a screwdriver or something to punch out the bottom part of the rivet. It will fall into the exhaust, so you better be ready to move forward and don't give up. You can't get it out without removing the end cap.
4) Using a drill may heat up the carbon fiber around the rivets. This will smell, but more importantly, it will melt the resin holding it together. This made my inside metal parts stick to the carbon fiber in certain places by the rivets. I had to use a screwdriver to separate the carbon fiber from the steel in those spots because I couldn't hammer it out. It was sort of "glued". Once I got that done, it popped right out.
5) A Dremel tool with a metal cutting wheel cuts it like butter. It was a very clean cut and I didn't even have to grind any of it down afterwards.
6) When putting the rivets back, be careful. My last rivet was loose when I put it in the hole and the nail part fell into the exhaust. I had already spent a lot of time getting it back together. I was able to get it out by wedging 2 screwdrivers between the carbon fiber and the metal part of the exhaust to give it enough room where I could grab it and pull it out.
If you want the exhaust to be much deeper and a bit louder, this is the way. You don't gain any horsepower or anything because it still has a cat. If you want more horsepower, you will have to replace the entire exhaust with one without a cat. It's on my list, but I've already done so much more to the bike (new spockets, Gabro Racing stacks, Sprint Filter, reprogamming with UpMap, etc.) and it is much faster and way more responsive now already.
To me, it was worth it even though I thought about punching a lot of stuff during the process.

[@franciscojuanchi6052]

@@irkdhesa I hold hardly agree that it made my bike sound a hundred times better!!! It definitely was worth a little bit of a headache.
As far as the process to remove the OEM rivets. I never had a problem with any of my 3/16 metal drill bits braking. However when I originally started, I was using 1/8 metal drill bit and then went up to a 9/64 which, to me, made the process a bit of a pain.
Once I went to my local hardware store and picked up (2) 3/16 Drill bits it helped a lot. Getting some of the rivets out once you punch through with the drill bit was a bit of a pain at times.
When it came to putting in the new rivets, I used a one-handed rivet gun to set the rivet or get the rivet halfway set. Then I used a two-handed rivet gun that looks similar to a pair of bolt cutters. That allowed me to really squeeze and eventually set and break the rivet off.
In the video you seen where I used a aluminum 1/4 inch rivet, that was because I accidentally bored out the hole and made it too big for the 3/16 rivets. This was because I was using a smaller drill bit and trying to waller it out. This to me was by far the most challenging part of this process. There was a few times where I was trying to set a new rivet in the hole and for whatever reason my rivet would not set properly and would fall into exhaust therefore I would have to redrill the rivets that I had already set. But again, with that 3/16 drill bit that i had, it was fairly quick and simple for me.
Again this was my first time doing it and there was no videos on how to remove it. All I seen was a bunch of random post that was kind of all over the place and none of it ended up actually applying to my bike. I'm definitely confident that if I were to do this all over again it will be fairly simple.
Regardless I'm glad that you did it and you're happy with the results because I definitely was!!! It was totally worth it. Thanks for watching I'm glad I can help out a little bit. Cheers mate 🍻

[@ariels9885]

Damn, exactly what I was looking at doing on my Extreama! Thanks Man!

[@franciscojuanchi6052]

@@ariels9885 your welcome brother!! Any questions I'll be glad to help my man!!

[@Didiplouf12]

I really wants to do this on mine

[@franciscojuanchi6052]

@@Didiplouf12 definitely with it man... Any questions ask brother!! The video doesn't do it Justice, the growl is so much deeper...

[@komoore87]

Total noob questions but what size rivets did you use? never worked with them before

[@franciscojuanchi6052]

@@komoore87 not a noob question brother, I added a 3/16 stainless steel rivet. Got it from Amazon

[@MegaTrotz]

@@franciscojuanchi6052do you have a link to the rivets you got? Awesome video I am going to do this to mine until I get a full system and tune I want

[@franciscojuanchi6052]

@@MegaTrotz SDTC Tech Stainless Steel Blind Rivets 3/16" x 3/8" (6-4) Open End Type Pop Rivet Grip Range 3/16-1/4 inch (50 pack)
a.co/d/8Ac2p65

[@franciscojuanchi6052]

@@MegaTrotz Make sure you get a rivet gun that's got a strong enough bite to snap the rivets. I used a one-handed one to get the ribbit almost set and then I use my two-handed pair to Cut it off

[@MegaTrotz]

@@franciscojuanchi6052 Perfect. I work at a car dealership I'm sure we have some good ones there. I am just going to take off the "slip on" part and bring it in the shop with me tomorrow