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[Dracula]

I'm in the process of changing the baffles in my stock mufflers, I grind the welds, start hitting the baffle to break the welds loose, and a bolt with a washer welded to it, along with a few extra washers falls out!?!?!  Why on earth would this be in the muffler?  It was the right side muffler.





The engine end of the baffle looks like it never had any exhaust through it.

[bobroadglide]

I'd be willing to bet the bolt and washers are from the tooling jig that is used to hold parts together during the weld process.  Wonder who builds the mufflers for Harley these days...might be someone who works there could tell, if they would.  You ought to mention this to Customer Service at HD headquarters.  Anything happens to your motor in the future from running with one muffler plugged up could be a warranty issue.  At least you would have it documented.

[Twolanerider]

Someone else showed a similar plug some months ago.  So it's not a one-off screw up.  It was explained at the time as a plug used in the manufacturing or plating process (don't remember which--wasn't paying attention that close). 

[Twolanerider]

You ought to mention this to Customer Service at HD headquarters. 

In a different era that would absolutely be so.  Now, however, you just about have to be glad you found it and count your blessings.  Otherwise you stand the chance of a dealer responding with "and what were you doing to the federally prescribed exhaust/emissions system to have found this?"

[sadunbar]

In a different era that would absolutely be so.  Now, however, you just about have to be glad you found it and count your blessings.  Otherwise you stand the chance of a dealer responding with "and what were you doing to the federally prescribed exhaust/emissions system to have found this?"

I was thinking the same thing...  How quickly the tables turn...   

[MAT]

 Otherwise you stand the chance of a dealer responding with "and what were you doing to the federally prescribed exhaust/emissions system to have found this?"

This is why I don't see the sense in drilling out (removing) the CAT as oppose to installing a CAT less pipe and having the MOCO CAT pipe ready to reinstall no mater what the reason might be.

[tcb62]

Mat,

My thoughts exactly: change the whole exhaust and keep the original ready if needed to be reinstalled.  Just look at the recent court cases in Maine and Mass, this may be a big issue in the future!!!

[WestCoastRuss]

This is why I don't see the sense in drilling out (removing) the CAT as oppose to installing a CAT less pipe and having the MOCO CAT pipe ready to reinstall no mater what the reason might be.

This may be a more expensive solution up front but cheaper insurance for us in the long run "no matter what the reason might be"

[MAT]

This may be a more expensive solution up front but cheaper insurance for us in the long run "no matter what the reason might be"

EXACTLY RUSS !!