Decided a couple of weeks ago to put the 2" baffles back in the Harley.
Why?
I've been having a hard time writing a tune that will run with the 2.5" baffles on the truduals.
I'm figuring not enough back pressure for the configuration of all the mods?

Tools needed.
1/2 gearwrench
3/16 hex head with 1/4 hex drive rachet.
Masking tape.
Home made baffle puller.
Hammer.
1/2 rod stock to be used as a driver.
Approximately one hour to do.
Sometimes taking the whole pipe off is required along with some penetrating lube and driving the baffle out of the inlet side by using a 4'-0" piece of pipe and hammer.

Here's the 2" baffles needing the repack.
Next to them the package of sport packing from www.fuelmotousa.com.

Here's the home made puller.

Here's the puller being used to pull the 2.5" baffles.

Now I'm laying out the new packing material for the 2" baffle and getting ready to wrap it.

Here's they are wrapped and this is what the masking tape is used for to help hold it on and it will eventually burn away.

Now they are being put back in the pipe.

Line up the hole for the retaining bolts and reinstall them. Some persuasion may be required to line everything back up, that's what the hammer and drive rod are for.
The bike was washed after the project was completed.

 

You should have cut those baffles in half.

 

I know little to nothing about motorcycles. Are these baffles and packing supposed to reduce noise? Kind of like a muffler?

 

Yes that is the "muffler", it's like a re-buildable glass pack.

 

a friend of mine has a harley, and when he bought it the baffles were already taken out, its to loud and he says he can get better gas mileage if he puts baffles back in it, is this true?

 

Probably.

Might increase low end power, too.


And to the OP, I've used the 'string' type packing for years in my dirt bikes and IMO it lasts much longer than the 'mat' type of packing.

 

That's good to know!

 

Here she is all cleaned up.

The mufflers used in this thread are made by Rush Performance along with the trudual header pipes.

 

^ gorgeous.

 

Pretty bike, 88!

- Jack

 

Very nice bike!