I would like to remove the packing from a 1997 FLSTS stock exhaust part #65986-97. I have removed the muffler and endcap and tried "tapping" out the baffle with a wooden dowel and a hammer without success...is there a weld that I should grind off or a step that I've missed or should I break out a persuader (larger hammer)? I don't want to bend/break any of the interior components but I'm hellbent on getting the baffle out...any help would be appreciated.

Thanks in advance.

 

Good luck! The baffles are spot welded in 3 places on the pipe end of the muffler. I bought the HD touring mufflers that come with different end caps and tried the bigger hammer trick only to have the spot weld tear a hole in the muffler on the outside. Now it is trash. FYI...I bought the set for $350 + the price of the end caps, Called the dealer to get a price on 1 and it was $200 [&o]

Barry

 

You can leave the pipes on the bike and do this, or hold on to them/brace them wrapped with a towel, etc. so you don't scratch them.....

Come in from the tailpipe side with a Hole-Saw. Have to check which diameter will fit in there. The hole saw blade has to be made for cutting metal, regular one's won't cut it!

The other option is to take the mufflers and cut about 3/4 of an inch off of the back, then the baffles just fall out!

After doing this, you may find that you've lost a little torque. It's very common that just removing the baffles can kill low RPM torque, as you're removing all of the backpressure.

My suggestion is, try it!!! if you don't like it later, then get some different mufflers. S&S mufflers are top notch!

joe