I posted this on the tech page but havent gotten any ideas yet, this board seem more popular so here it goes. I have Rush slip ons with the 2.0 baffles in them, they are too loud for me so I just got in a pair of 1.5 baffles. I was trying to get them into the muffler and they do not seem to fit. The 2.0s were tight comming out but they did, when I tried to slip the new ones in they will go most of the way in and the rear wide part will not go into the muffler. I tried banging and all that I know without going crazy on it. They appear to be the same diameter as the old baffle. Anyone have any ideas about how to get them in or similar issues?



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Same thing happened to me. I sprayed the ends with WD-40, then jiggled them till they slipped in. (Try to keep the oil off the fiberglass.)
The WD-40 also helps you rotate/move the baffles around to line up the bolt holes. Once the holes were close I used a Phillips screwdriver in the holes to get them aligned properly.
Once you change the baffles out a time or two you get the hang of it and it goes quick...

Hope this helps!

 

If the WD40 works let us know how they sound? I ordered the Rush with 1.75 baffles and if they are too loud I'll be do'in the same thing you are!

 

The 1.5's are pretty "muffled" sounding at first, especially compared to the sound of the 2.0's, but as they burn in the sound gets a bit louder and deeper.
I like them because they bark when you get on it but they're very quiet at cruise...

 

OK here is the scoop, I got the 1.5s on and went for a short ride. In my opinion they are the perfect sound not too loud and have that Harley rumble. I can here the stereo good. Getting the new baffle in was a bit of a challenge but nothing a small hammer and a piece of wood didnt handle.

 

got the 1.5son today and went for a ride, they are perfect IMO the WD and a piece of wood to bang it in did it. The stereo can be heard and they sound good.

 

Glad they worked out well for you!

 

Anyone know if the WD40 has any affect on the 02 sensors?

Peace,

 

Considering the 02 sensors are up by the cylinder heads and the WD-40 is being sprayed on the muffler baffles downstream at the end of the exhaust system, it should have no effect at all on them.

 

i know it smells as its burning off, though i was on fire.