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[gg]

Today I started installing the Fullsac CVO replacement cores in my 2009 FLHTCUSE4 muffler bodies.
I noticed that Fullsac's directions say to drill the bolt hole 1.5" in from the rear edge of the muffler body.
Following that instruction leaves the inlet side of the replacement core about 1/4" from contacting the front end of the muffler body inlet.
Is that the way the replacement cores are supposed to go in?
Or if you drill the bolt hole at 1.75" instead, then the inlet end of the replacement core is snug to the inlet end of the muffler body.
Wouldn't it be better to have the replacement core snug against the front of the inlet end of the muffler instead of hanging back 1/4"?
Would installing the replacement core snug to the inlet end of the muffler body result in some sort of heat related discoloration of the exterior muffler body if installed snug to the inlet?
Anyone who has installed the cores may have observed what I am seeing and I'd sure like to hear from you on how you dealt with this.
Thanks

[Boatman]

I've installed 3 sets of cores and drilled them all at 1.5" and the front ends of the baffles were snug against the inlet end.  Lay your removed baffle next to the Fullsac baffle and see if they are the same length from the inlet end to the end where the rear flange is.

I can't offer any help but the front end has to be supported so it doesn't vibrate.  When I put the baffles in, I put a wood handle hammer in the inlet end to center the baffle over the inlet insert.

When you look in the inlet end, there must be an insert inside.  Make sure you can see this insert sleeve and that you didn't drive it out with the baffle.

[Fullsac Performance]

Today I started installing the Fullsac CVO replacement cores in my 2009 FLHTCUSE4 muffler bodies.
I noticed that Fullsac's directions say to drill the bolt hole 1.5" in from the rear edge of the muffler body.
Following that instruction leaves the inlet side of the replacement core about 1/4" from contacting the front end of the muffler body inlet.
Is that the way the replacement cores are supposed to go in?
Or if you drill the bolt hole at 1.75" instead, then the inlet end of the replacement core is snug to the inlet end of the muffler body.
Wouldn't it be better to have the replacement core snug against the front of the inlet end of the muffler instead of hanging back 1/4"?
Would installing the replacement core snug to the inlet end of the muffler body result in some sort of heat related discoloration of the exterior muffler body if installed snug to the inlet?
Anyone who has installed the cores may have observed what I am seeing and I'd sure like to hear from you on how you dealt with this.
Thanks

When things get hot they will grow. Even the factory cores are not seated all the way in when cold, this allows for expansion. 1.5" gives you a little room for error in both directions should you miss a little with the drill. Even fully bottomed out most likely won't cause any problems. Don,t over think it. Its a Harley, not the space shuttle. Lol......

Steve

[flyin-r]

I did mine exactly as Steve says. !.5" to allow for heat expansion and it works fine. No rattles and no problems. His "X" pipe fits perfectly as well. The TTS tuner and software installed without problems and make the package complete. Highly recommended!

[cahdbiker]

Fthngrg, The stock baffles are flared at the front end. They slide over the inlet end. They have to slide over the inlet to be supported at the front. I drilled the holes as per Fulsac's recommendations and it worked fine on the left side. However when removing right side stock baffle a portion of the inlet pipe came with it and left a small hole in the muffler body where the weld let loose.(this happened to someone else on the site also) There was still an additional piece of inlet pipe remaining in the muffler body. I took the portion of the inlet that came out and slipped it inside the Fulsac baffle then reinstalled it so it slipped back onto the remaining inlet pipe. I had to braze up the small hole in the muffler body(can't see it because it is under the heat shield) and also had to drill a second hole at 1.75" to get it to fit snug. Everything seems to work fine and I have no rattling. I recommend the Fulsac stage one set up, 1.75" baffles, HD high flow air cleaner, and non cat header. I have a lot more power. I don't feel as though my mileage has been affected, and the sound is just right for my taste. Slightly louder at idle, a little louder upon acceleration and whilie cruising it is mellow and  you can hear the stock stereo with no problem. When it was stock it pinged intensly when out of California (probably out of state gas). I will make a post after my vacation to update on the pinging if any with the fulsac stage one set up and non California gas. The reason I think it was the gas is because as soon as I filled up my first tank back in CA. the pinging went away. Also, if you haven't changed your air filter yet I  posted a parts and price list for the HD high Flow kit with K&N filter. The price was right and if you buy the parts separately instead of the kit you get a chrome breather. Good Luck CAHDBIKER

[FL54]

cahdbiker:
I don't know where you went out of the state of CA but here in Oregon they passed a screwed up law requiring 10% ethanol in the fuel.  You can find places that sell non ethanol gas but you have to look for them.

[cahdbiker]

cahdbiker:
I don't know where you went out of the state of CA but here in Oregon they passed a screwed up law requiring 10% ethanol in the fuel.  You can find places that sell non ethanol gas but you have to look for them.

FL54, We were in Nevada, Utah, Nebraska, Wyoming, and Idaho. The bike, 09SEUC, performed well in stock condition, but the pinging drove me nuts until I got some CA gas back in the tank.I noticed in some areas the Supreme was 92 Octane as opposed to the 91 we have here, but it still pinged. I hope to be cruising thru our state late this summer so I will look for the non ethanol gas. Thanks for the tip. CAHDBIKER

[gg]

CAHDBIKER, thanks for the info. I got the 2.25 baffles installed in the original cans w/o incident and flashed the ECM last weekend and am installing the Ventilator AC tonight, so I should be able to ride this weekend if it doesn't rain.

[FL54]

Roger that CAHDBiker.  Ride safe.  The legislature made exceptions for boats and aircraft so if you con't find non ethanol fuel try a marina if there's one nearby.

[cahdbiker]

Roger that CAHDBiker.  Ride safe.  The legislature made exceptions for boats and aircraft so if you con't find non ethanol fuel try a marina if there's one nearby.

FL54, I never thought about going to a marina. How about a small airport, you know they have good fuel. The 100 Octane that I used to use when I had a built up evo with 110 lbs of cylinder pressure is $7.49 per gallon now. Glad I don't need that anymore. Take care. CAHDBIKER