How hard to remove baffles from Rush mufflers?
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Cruiser
Joined: Oct 2008
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How hard to remove baffles from Rush mufflers?
I'm going to be helping my dad replace the baffles in the Rush mufflers on his Ultra Classic. How hard is it to pull them out once the set screws are removed? They've only got about 3,000 miles on them so there shouldn't be too much corrosion or carbon build-up.
Road Captain
Joined: Jul 2009
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From: Tea, SD
When I pulled mine this last weekend to check the condition of the packing at 2000 miles they came out relatively easy. The problem I ran into was the masking tabe used to hold the packing on the baffle turned brittle and wedged as I pulled both baffles. Part of the packing wanted to do this also.
Never even took the pipes off the bike.
The tool I used was an autobody slide hammer with a homemade hook attachment.
Also put some fiber glass tape on the packing this time, hopefully that works better.
It was kind of a chore to get the baffles lined back up with the hold down screw.
Got the job done in about 45 min.
Packing material was brown and hadn't deteriated that much.
Never even took the pipes off the bike.
The tool I used was an autobody slide hammer with a homemade hook attachment.
Also put some fiber glass tape on the packing this time, hopefully that works better.
It was kind of a chore to get the baffles lined back up with the hold down screw.
Got the job done in about 45 min.
Packing material was brown and hadn't deteriated that much.
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Ron
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Thanks but I have plenty to do here. I have over 12K on my 09 EGC, still sounds great! Is there a certain mileage you have to check the baffles? Is your dad having problems with his Rush mufflers?
Cruiser
Joined: Oct 2008
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From: Concord NC
My right side came out easy, the left not quite as easy.
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Cruiser
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The reason we pulled the old baffles out was to put in bigger ones. I think the mufflers came with 1.5" or 1.75" baffles, and he bought some 2.5" ones. Both came out without any trouble.
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Road Warrior
Joined: Sep 2007
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From: Taylor Mill Kentucky
After about 2k miles, I pulled mine out to take the wrapping off. Bike sounds much better now.
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Joined: Jun 2009
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From: Wellsboro, PA
I don't have one of those tap/slide hammers, or whatever you call them. I pulled mine out with a wire coat hanger. There's a bar on the end of the baffle where you can put the hanger & pull. "Un-twist" the hanger until it's just one long piece of wire. Put one end behind the bar, back out the end of the pipe, put the ends of the hanger together in your hands & start yankin"! They might come out hard. Mine did. It's because that foam/cloth packing comes unravelled & gets wedged on the sides, but they'll come out with a little work. One side was easier than the other, so it just depends. I wanted more loud, so I pulled the baffles & put larger, new ones back in.
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Joined: Sep 2007
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From: Slidell, Louisiana
Shoot some WD-40 up in the pipe and get a coat hanger or something to grab the cross bar on the baffle. I used a nail puller i had but anything with a hook on the end will work. Mine came right out after 6k. Packing was gone in the right pipe so i pulled out the rest in both and ran like that for another 2k but could not stand the high pitch ping sound so i pulled them back out and wrapped them with fiberglass cloth that i purchased from ACE hardware. 1 bag for each pipe. Much better sound and the cloth has outlasted the packing already. total cost for doing this was around $10.