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[LarryB]

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[Techie0212]

In like FLINT . . .  Awesome delivery just when I thought it would come in, it was at my doorstep.  Thanks Steve. Got the bike all prepped with the baffles all removed. Now to have it ready for the weekend. Gonna be rainy here in Hawaii for the Marathon week, but who the hell cares when I can rumble with these 2.5 baffles.

More to come about the insert. I have to say that the toughest part of all was to remove the welds and make sure that there were no places in the exhaust tube to impede the removal. It is easy, but the experience to do that for a non mechanic is precious. A Carborundum disc is way better than the stone or the carbide. Much quicker.

Aloha, Techie

[1abastarsmda]

Putting them in is extremely easy.  Just slide them in to match your drilled hole, tighten the one bolt, and you are ready to put everything back together.  I am assuming you meant to say 2.25"...I don't think they make a 2.5".

[Techie0212]

TYPO - Had to look back and you're right...but the remedial part of placement is to put the baffle in the muffler, tighten screw. Then attach the heat shields and end pipe. Finally attach to the headers.  Correct?

Thanks,

Techie

[1abastarsmda]

Might take you ten minutes per side or so, but not a lot to it.  It makes it pretty easy, since you were the one that took it apart recently, so you know just where everything goes.  Toughest part for me was a little struggle getting one of the endcaps back on.  Believe me, if I can get this back together quickly, ANYONE can...I usually move a little slow in getting these things done.

[Techie0212]

Got it all together and hit the switch. OMG. Can't hear the radio!!! This was in the garage and not the open air outside. I think it has to be louder than the 2:1 Thunderheader I had on my 2003 RoadKing. Might be thinking of going to the 1.75 instead. Then again, more air flow... The baffles look beefy from the rear... BTW the measurement for me was 1 2/8 instead of the suggested measurement. Found that out on the predrill preparations. I did leave in the fiberglass. To try again today and ride around the block. Still rainy conditions, but nothing falling down yet. Thanks again Steve @ Fullsac... I have shared this with my Waipahu HOG group... 

Aloha,

Techie

[1abastarsmda]

Got it all together and hit the switch. OMG. Can't hear the radio!!! This was in the garage and not the open air outside. I think it has to be louder than the 2:1 Thunderheader I had on my 2003 RoadKing. Might be thinking of going to the 1.75 instead. Then again, more air flow... The baffles look beefy from the rear... BTW the measurement for me was 1 2/8 instead of the suggested measurement. Found that out on the predrill preparations. I did leave in the fiberglass. To try again today and ride around the block. Still rainy conditions, but nothing falling down yet. Thanks again Steve @ Fullsac... I have shared this with my Waipahu HOG group... 

Aloha,

Techie

Are you sure you got the baffle seated the entire way into the muffler?  I had to stand my muffler up and drop it on the front end of the muffler several times before it seated in there the entire way.  I knew it was there once it matched up with the hole I had drilled.  Nobody else has mentioned a difference in the measurement to drill the hole and it was about right on for me.  Also, you were in the garage when you started it up.  It should sound a lot louder in the garage.  Better back it outside.  They have some tone to them but I don't think they are that loud.  Certainly not enough to drown out the stereo

[Techie0212]

Spun it around the block and loved it since. Stereo is fine. The look is beefy from the tail pipes. Heat buildup from the pipes are less even with Xied hooked up. This is in shorts, and sandals. Best 20 min ride.

Aloha,

Techie

[Spazz]

I got this reply last week under the topic heading "Total removal of our Cats 09"

Spazz, I have dissected just about every brand of muffler ever made. V&H Bassani ,S&S, Cobra, Wild Pigs, Rush, Supertrapp, SE,Samson, ETC, IMHO other then Supertrapp With there Tuneable Discs, And the tuneable Bub Mufflers there is very little difference, In Muffler baffles, in fact some of the major Brand baffles will interchange, I am not a performance addict but many of my friends are, and from most dyno runs  Ive seen, it takes one awesome engine to support 2.25 baffles without a noticeable loss of low end torque, 3 additional HP at 5800 rpms is ok for bragging rights but not at the loss of 5 hp at 3000 rpms ,sometimes less is more.

Has anyone else experience power loss with the installation of the 2.25" cores?

[1abastarsmda]

I just started my bike and put my hand behind each muffler.  There is plenty coming out of the right side, but the left side has VERY little exhaust being routed that way.  I keep thinking that you could plug the left side pipe right where it makes the little bend out of the cat converter chamber, and then slip the left pipe back on and leave it as a dummy pipe.  Anyone have thoughts on what this might accomplish?  It seems as though it would turn the system into a 2 into 1.  Would that yield any positive results?

[HOGMIKE]

I just started my bike and put my hand behind each muffler.  There is plenty coming out of the right side, but the left side has VERY little exhaust being routed that way.  I keep thinking that you could plug the left side pipe right where it makes the little bend out of the cat converter chamber, and then slip the left pipe back on and leave it as a dummy pipe.  Anyone have thoughts on what this might accomplish?  It seems as though it would turn the system into a 2 into 1.  Would that yield any positive results?

Take a look at your stock mufflers, if they are like mine there is less restriction on the left than on the right. The internal baffles are totally different from left to right. I noticed when running the stock system there was equal pulses from each side. Like you, when replacing the mufflers and/or baffles, you would PROBABLY notice more from the right side (path of least resistance). Not a big deal, as you will probably get enough flow with your new setup. Enjoy the sound!
I think most of us are waiting to see a dyno comparison from the stock to the fullsac's to V&H or whatever.....I still believe you will not see much more than a 5-9HP difference with just muffler changes.
Have you taken the bike for a run? Notice any changes in sound?? Pleasant or annoying?? I think you will like them!
But, to answer your question, I would not plug off the crossover to the left pipe. I don't think you would gain anything.
Mike

[HDDOCFL]

Talking to two local dealers about muffler changes and both say they will honor the warrinty with any muffler changes, but will not with any mods to the cats on the CVO bikes, or any tunning devices witch they do not install, so for me it looks like my options are limited as I want the warrinty in to stay in tack. I plan on the Fullsac 2 1/4" baffles and if they are not what I want will add the super trapp disc set up to them to quiet them down and If I notice any drop in power also due to lack of back pressure, but I assume with the cats in place I will not have a back pressure problem. I await nightriders 09 ideas and hope he has something like the XIEDs for the 09 110" motors as these leave not trace that they were on the bike.  Thanks Doc

[nautilus]

Thanks to everyone on this thread who has contributed to the "do's and don'ts" and "tips and tricks".

I'm not a Wrench yet, but I do believe I'm on my way...   I just removed my entire exhaust all by myself without scratching or damaging anything 

Monday I'll be ordering the 2" cores from Fullsac along with a Master Tune. Soon enough I'll be good to go.

Question:  When I removed my header pipes, I also removed the compressed gasket seal that inserts between the header pipes and engine.  The gaskets were silver in color.  I had seen them colored copper before... Is there a difference in quality and is there a specific p/n that might be suggested..?

Thanks again All!

[09 S/T FLTRSE3]

Talking to two local dealers about muffler changes and both say they will honor the warrinty with any muffler changes, but will not with any mods to the cats on the CVO bikes, or any tunning devices witch they do not install, so for me it looks like my options are limited as I want the warrinty in to stay in tack. I plan on the Fullsac 2 1/4" baffles and if they are not what I want will add the super trapp disc set up to them to quiet them down and If I notice any drop in power also due to lack of back pressure, but I assume with the cats in place I will not have a back pressure problem. I await nightriders 09 ideas and hope he has something like the XIEDs for the 09 110" motors as these leave not trace that they were on the bike.  Thanks Doc

That's insane. So if you put a D&D 2 into 1 or a set of Reinhart true duals on your bike it will void the warranty? That's just nuts! Before you make a decision, you should speak to a few more dealers. Their policies all differ greatly. In this area there are those that say any mods except mufflers will void warranty, and others that will allow different headers, cams, throttle bodies, etc without voiding.

I switched out the 09 cat headpipe for an 09 non cat, installed 2" Fullsacs, and downloaded the generic SESRT map for my application myself. I am going to take it to a local dealer for tuning / dyno, but they are aware of the mods I have made and my warranty will not be effected. Shop around.

Cheers, Ken 

[1abastarsmda]

Mpst dealers don't even know that there are cats in the exhaust pipes.  Assuming your dealer knows they are there, ask them why it's okay to change the mufflers, since the previous models had the cats in the mufflers themselves.  It sounds like they were okay with that.  As far as the Fullsac 2 1/4" baffles, I don't think you will need the Super Trapp disc setup to quiet them down.  They aren't that loud.  If you think you will want them any quieter, get a smaller size Fullsac.  That will give you a little more back pressure and even less volume.  They sound great, but I don't think anyone considers them to be loud.