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Sportster Motorcycle Air intake, Carburetor, EFI, Fuel, and Exhaust Problems, advice and/or how tos for Sporster and Buell motorcycle carburators, Electronic Fuel Injection (EFI), Air Intake, Fuel and Exhaust.

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  #51  
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There's another thing I found with the Rush mufflers. The baffles are pretty small compared to their advertised size.

On their 1 3/4" baffle the biggest OD socket I could run thru the baffle (have to have the baffle out and go from the inlet end due to the bar across the outlet end) was 1 1/8". 1 3/4" baffle with louvers deep enough its' actual ID is ~1 1/8". I got a set of 2" baffles. The actual core is the same but the louvers don't protrude as deeply. The 2" baffles seem to want ~6% more fuel at larger throttle opening compared to the 1 3/4" baffles.

This isn't a complaint, I like the mufflers, just something to be aware of.
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  #52  
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I was actually going to go with the 2" when I was considering them. Little deeper and louder.

The HP Plus baffles are all the same diameter except for the end they attach to the pipe/slip on to center them. Just different lengths. More golf balls as I call them.
Thought about cutting my current ones shorter. One golf ball at a time. Add more top end and a little louder. I've got another set here with 3 but for a 2" pipe. I think the ones in the slip ons have 5. The ones I had in my drag pipes had 4. The exhaust goes thru them and around them with narrower passages between each golf ball which is how they diffuse. They really are a unique looking baffle.
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