Removing Baffles from Stock Harley Exhaust

Mike has the Evolution top end completely assembled. He left off with the top motor mount installation. Now, he is on the opposite side of the motorcycle, preparing to install the exhaust system. For this 1988 Heritage Softail, Mike will be reinstalling the original factory exhaust system. The only difference is he will be removing baffles from stock Harley exhaust prior to completion.

There are two different style exhaust gaskets that can be used for Big Twins and Evolution Sportsters. The stock-style exhaust gaskets are conical in shape. There are also aftermarket gaskets that are flat and not as thick as the stock gaskets. Sometimes, the aftermarket gaskets are needed for performance exhaust systems. However, for most applications, it is better to go with the stock conical-shaped gaskets.

These gaskets consist of more material and therefore are more forgiving for a wider range of combinations and variables. Mike installs the front and rear exhaust gaskets by simply pushing them in evenly until seated and will remove baffles from stock Harley exhaust.

The exhaust is carefully lifted into position, and the front and rear exhaust flanges are located over the exhaust studs. Mike has lightly lubricated the exhaust studs with Anti-Seize and has already purchased a set of four new flare nuts to replace the original flare nuts. Mike starts the four exhaust flare nuts and the two rear exhaust bracket bolts by hand. The flare nuts are now alternately tightened in small increments. After the flare nuts are tightened, Mike final tightens the two bolts that retain the rear exhaust bracket before removing baffles from stock Harley exhaust.

The exhaust flare nuts will be checked again, or re-torqued in 1K miles. Finally, the heat shields are set into position and worm clamps are snugged down with a screwdriver. Now to removing baffles from stock Harley exhaust. Mike uses a hole saw to drill out the baffles from the stock mufflers. This is a cheap way to achieve a more free-flowing and audible air flow.

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