Installing Fullsac Baffles

I finally got around to installing my Fullsac 3/4' baffles today. The first step is to remove the exhaust from the bike. First you loosen the.

Found this thread: and have read about the new 4' CVO mufflers on the various boards. My understanding is that after 2009 they began to put the catalytic converter in the header pipe (crossover) so the mufflers are 'clean'. They call them 'quiet power' - why(?) I thought. So I picked up a new takeoff set off eBay for real cheap. They look great - huge 4' chrome bodies with heat shields and billet aluminum end caps. Put them on my '02 (had to remove the heat shields) to see what they might sound like stock.

They were f'n QUIET! Sound like a sofa cushion wrapped around the back of the bike. Looked at Fullsac who makes a nice looking upgrade baffle kit: But before I go that route, I thought I'd try a mod that I found described on another forum. Seems the latest version of these has some sort of emissions or restrictor 'plug' just inside the exit end that can be drilled out with a hole saw. So $20 and about 10 minutes later, the 'plugs' are out. Attached are some (reference) before and after photos.

What this basically does is make this a straight-thru design, similar to the smallest 1.75' Fullsac baffle. Ok installed them again.

Still pretty mild volume level, but noticeably louder. Bike definitely runs better (normal again) with the plugs out. Tone is definitely lower and fatter than the Screamin Eagles I had previously installed. Doesn't have much straight pipe snap or tinny sound, which is what I was absolutely trying to avoid. However, what is really interesting about these mufflers is how the volume changes with RPM. Idling and very low speed they are nearly as quiet as stock mufflers, which is great when out of town and putting through towns or residential areas.

But on the highway you can hear 'em well. Not loud enough to need ear plugs and definitely not loud enough to piss off people, but definitely loud enough to be heard. Hard acceleration, they really bark. Stays nice and throaty and never tinny, a lower tone and volume than say a Reinhart or Vance and Hines.

Might be worth a try if you want a mild sound with good looks and driveability that won't get you a noise headache or unwanted attention. You can always do the Fullsac mod if the 'plug' removal isn't loud enough. Best part is the housings are stamped with 'emissions and noise' compliant verbiage LOL. I have a set of 2006 CVO takeoffs I bought at a Swap meet for $20. They had the Catalytic converters inside them. I took the Cats and the Fiberglass out and they were still stock quiet. I took the Baffles out and drilled 1/2' holes on each end where they divert the exhaust into the chamber.

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You can see through the mufflers but it still sounds stock until you get on it and then it opens up. Those Cats in the header pipes really muffle the sound.

I didn't try it but I bet you could almost take the mufflers off and still be legal. I have had a lot of comments on how good they sound and no one would know they have been stripped and drilled. Yeah the early ones have the cats, until 2009 or 2010 based on what I've read. Those are great candidates for the fullsac mod or what ROR did. Then the cats went to the header pipe. 2010-2011 seems to have a more conventional baffle (still quiet) whereas the 2012-2014 seem to have this latest baffle design with the 'plug'.

From what I've read, I'd agree, the header catalyst material is a huge sound deadener and most anything but an empty muffler housing will keep sound levels down. Guys who have removed this header cat have all commented as such. Here's a photo of the earlier (circa 2010-2011) CVO baffles, before the 'plug' version (illustrated previously), next to a Fullsac baffle. How this works is there are two tubes, both with 1/2 crushed ends, welded together crushed end to crushed end. What appears to happen is the exhaust has to flow out of the header end pipe then back around to the inlet of the exit pipe (red arrows in sketch). Free mp3 song download. Some of the exhaust flow also goes through the perforated end section of the exit pipe.

Flow on these has to be pretty choked. I've heard of guys notching out a section of the exit pipe as shown in the other photo (green markup in sketch) to enable more of a straight-thru pathway. I'd rather just swap the baffles for the Fullsac, Cycle Shack, or other aftermarket equivalent than to go through the headache of trying to make something really good out of that stock piece. There was some question as to whether or not the CVO mufflers with the 'plugs' removed and the aftermarket Screamin' Eagle 4' 'Street Thunder' mufflers have otherwise the same baffle. I checked out the SE mufflers at the local dealer and the baffles internally are definitely different. The SE's are a straight-through design like the de-plugged CVOs, however, the baffle ID appears to be slightly larger with additional perforations.