I just turned 20,000 miles and 19,000 are with the Rush 1.75" mufflers. I have no idea if the packing is out or not but they still sound and look good.

 

22,000 miles on mine. They are a little louder than when i put them on but i love em. No performance change so far. I havent pulled em out to check the packing, dont really care.

 

How hard is it to replace and is there any special process/instructions for replacing the packing in the Rush mufflers?

 

When I bought mine Jamie told me that with the origanal packing, it would last around 5,000 miles. I bought the new packing from Jamie after talking to him he said that the new packing would last around 20,000 miles. If you look at the average rider how long does it take to get to 5,000 miles? I know for most it is done in a short amount of time. When I received mine I took out the baffles and was amazed how little the packing was about a 1/4 inch thick. With the new packing it is triple that.

Not hard - there is a bolt on the bottom take that out and depending on how long they been on might be a little tough. Mine where new so came out very easy, I have read that some have had a little trouble but there is a bar on the end of them or some say take a pole and tap it out thru the end. Once out remove the old and split the bag of the new packing in 1/2 lay it out and roll the baffle then take masking tap and rap the ends and a few around the middle just so you can get it back in.

 

Here is mine after a little over 10,000 miles, this was the first time I pulled them off after installing them when bike was new....No big deal really... I bought Rush knowing I would have to repack baffles (at least once a year) When I repacked them this spring I took some advise from a old friend who has been riding probably longer then ive been alive. I have checked them a few times this summer and havent noticed any significant reduction of packing.

 

I went to auto parts store bought 2 bags of fiberglass Matt and some masking tape. Used 1 bag for each pipe. Easy job and the Matt will last a lot longer than the packing. Ace hardware has the Matt also.

 

Will losing the packing effect your backpressure? Or is it just for sound? When I got my stuff from Jamie I wanted LOUD. He tested my set up and suggested that I do not go any bigger than 2.25" baffles. He said after that performance really drops.