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Author Topic: Frustrated with Fullsac CVO Baffles install into CVO mufflers  (Read 6555 times)

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wolverine

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Getting really frustrated trying to install 2" CVO cores. They wouldn't fit in after removing the sock baffle. I found some slag harley had left inside. Removed it with a dremel and they still won't go in the damn mufflers. I made sure the inlet was lined up and the will only go in about 3/4 of an inch. If I reverse the cores the end which should be at the end cap slides in first it will slide in the opening about 4 1/2". So I have it ground down enough. Why is the inlet causing an issue? Bad cores or bad mufflers all I can think of. Seems like the flange on the cores wont let them seat correctly.
   Any have this happen to them or is it just my luck?  What can I do?
Shouldn't they just slide in and the bolt holds them?  I'm sick of having exhaust problems. I'd like to install this and be done, good riding weather is finally here. Thanks for any ideas. Rick
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muddypaws

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #1 on: May 11, 2013, 03:29:00 PM »

Unless you have something strange going om inside your muffler they should go right in. 
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tweeter13

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #2 on: May 11, 2013, 03:34:23 PM »

Lay the old muffler insert and the fullsac one down side by side the big end even.  I am sure they are the same length.
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dartman

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #3 on: May 11, 2013, 03:43:34 PM »

As already stated they should slide right in, I've installed probably a dozen sets of fullsac baffles a couple have fit snugly, but as long as the flare on the baffle inlet is properly aligned over the inlet pipe a slight tap should seat them easily.
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fastfreddy

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #4 on: May 11, 2013, 03:50:55 PM »

there is a sleve at the clamp end of the can (inside) that the core has to slip over, shine a flash light inside of the can to help you line it up...hope this helps? ???
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tweeter13

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #5 on: May 11, 2013, 03:51:36 PM »

Just wonder if the pipes are nor bike.  If the are off look in the small end with a flash light and make sure they are going in straight if they are not it may stop at about 3/4 of a inch which is what I suspect is going on.
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wolverine

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #6 on: May 11, 2013, 05:06:50 PM »

Thanks for all the advise. I just tried it. After getting the inlet aligned I have to give them a good whack with a 2x4 and a hammer and the did go in.
     I just wonder after using them awhile if I'll be able to get them back out without removing the mufflers. Maybe can get a strap wrench to work.
Another question or two  - What difference in sound is there using the stock screen with packing VS using no screen or packing? They are 2" cores.
- Anybod drill the 1/4" hole on the inside of the muffler instead of the bottom? Trying no make it a un noticable as I can.
Thanks, Rick
« Last Edit: May 11, 2013, 05:15:37 PM by wolverine »
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fastfreddy

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #7 on: May 11, 2013, 09:08:48 PM »

i used some of the stock packing and ended up pulling it back out & for me it sounds better with no packing, im running the 2.25 cores. i put the bolts on the bottom of the cans and dont see them at all,
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RonWa

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #8 on: May 11, 2013, 10:33:59 PM »

You will need to remove the mufflers, don't ask how I know :-)
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kiwihog

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #9 on: May 12, 2013, 02:29:36 AM »

dont the instructions say you should remove the mufflers for instal :nixweiss:
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wolverine

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #10 on: May 12, 2013, 09:51:33 AM »

Mufflers are already off the bike. I'm concerned about removing the cores to add or remove packing. Or swapping to a bigger baffle. I was hoping to do it without pulling them back off. As tite as they go on, I doubt theywill come out without a smack from the othe side. At least they shouldn't rattle. Thanks
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dartman

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #11 on: May 15, 2013, 08:42:47 AM »

Mufflers are already off the bike. I'm concerned about removing the cores to add or remove packing. Or swapping to a bigger baffle. I was hoping to do it without pulling them back off. As tite as they go on, I doubt theywill come out without a smack from the othe side. At least they shouldn't rattle. Thanks
I haven't tried it on CVO mufflers but I have an XL Iron I play with and a stuck Screamin Eagle baffle will loosen readily if you remove the attaching screw let it get hot and rev the engine
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nevadabob

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Re: Frustrated with Fullsac CVO Baffles install into CVO mufflers
« Reply #12 on: May 15, 2013, 09:08:29 AM »

I use Full sac 1.75 baffles as I want just a little more rumble, it was a easy off the Bike and I pulled the packing and screens. They just bunch and create hot spots on the can. They sound great with Jackpot headers.
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