I'm going to repack the baffles in my Rush mufflers and was wondering if the baffles come out easily? Also, are there any do's or don'ts when repacking the baffles?

Thanks!

 

Just pulled the baffles out of my road king (which is basically same for baffle removal). after taking out the bolt my baffles would turn a little but couldn't pull them out. I started the bike up to heat the pipes so they would expand...sure enough I was able to pull the baffle out with a little force, but it wouldn't budge until I heated it up.

 

You will actually just wrap the baffle rather than re-packing like on a dirt bike or some metrics. Keep the baffle material loose...lets the air move a bit better. Tight will force more exhaust directly out...but it will be louder.

 

Mine came out easy enough. Just remember that the screw on the underside of the pipe doesn't screw out. The nut inside the pipe screws off. Almost stripped out the screw before realizing this.

I used masking tape to hold the matting together while re-inserting the baffle. Same thing the factory does.



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2008 Heritage Classic: His
2008 Deluxe: Hers

 

mine at 15k needed repacked, and I called Rush and they sent me new new packing over night free last yr...

cut the length +1in and don't wrap tight...use 3/8 masking tape to wrap and don't worry about the heat.
after done it is really good.

take out screw and the baffle came out easy. just a little twist and its out. watch out for burrs on baffle, install the same way and muffler..

 

Thanks for all the tips! Hopefully I can get it done tomorrow after work or this weekend.

 

i found easy way to remove them. warm the engine and they should get loose. then use a garden stake and insert and use the barbs to grab the baffle. I used a 4ft stake and beat the stake with a hammer to loosen the carbon.