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I have decided that the Rinehart TD baffles don't come out! I took the end caps off and tried to loosen the baffles by putting a pribar down the tube and ricking the tube using the pry bar. No Luck. I ran the motor for a while to heat the mufflers up and still no luck. I rand the bike 75 miles or so with the end caps out and then tried to loosen them; again, no luck. I wanted the baffles out to make noise in a parade and found the removing the end caps gave enough noise. I have decided to leave the baffles alone. HD dealer said sometimes the muffler has to be removed and the baffle driven out.
They sure sound stubborn. When you finally get 'em out, butter up the ends w/ copper anti-seize. I can assure you the baffles are easily removable as I've had mine in and out 4-5 times.
The install calls for RTV silicone at the muffler/header joint. This doesn't affect the baffle but maybe the installer mistakenly used RTV on the baffle. Otherwise they're just seized up.
What ever you do, don't bend up the baffle.
I was in a parade where more noise was OK. It was not intended to keep them out. If I could get them out I might try the fiberglass wrapped sound as well as other baffles.
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