SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Sportster Muff - OK, I'm a moron... /cgi-bin/YaBB.pl?num=1142882689 Message started by caruso81 on 03/20/06 at 11:24:49

Title: Sportster Muff - OK, I'm a moron... Post by caruso81 on 03/20/06 at 11:24:49 OK, I've done a little wrenching...brakes, jets, carbs, new horn, windshield, tires...nothing big, but some, and I must be particularly thick today, because there is something I'm missing... I just got a pair of 05 Sportster mufflers from eBay. (anyone need one?) They seem correct for the Sportster because this info is shown on the stamp on the mufflers -- XL883/1200. Great. I got my stock muffler off without wrecking anything and I am getting the 7" 10-deg extention pipe made. No problem. Jets and a K/N filter are waiting patiently, and I have various spacers for the carb (stock is in there right now). Cool. These mufflers don't use a mounting tab, but they have square nubs and two bolts directly into those, one of which will fit right onto the rail (I may need a new hole). OK. The heat shield is an issue, but I'll find a universal one online. But what I don't get is the round hole/opening that extends 90-deg out from the muffler about 2" down from the end where it will mate to the pipe? It is almost like another smaller pipe comes out of this. This opening can't be left open, but it doesn't seem like it will necessarily be tightly closed off when the muffler goes over the extension (or will it?). Does this late model muffler no longer work for the Savage? Or do I need to get some type of plug welded to cover this opening over? Ideas? And does my confusion indicate that I ought to stop screwing with my bike? Thanks, Wayne Crannell

Title: Re: Sportster Muff - OK, I'm a moron... Post by USCG Cremeans on 03/20/06 at 13:30:11 maybe its a muffler from a california model.. having to due with some sort of smog reducing device?  thats my only guess. good luck jesse

Title: Re: Sportster Muff - OK, I'm a moron... Post by Max_Morley on 03/20/06 at 13:49:50 I think I've see some versions that used a balance tube between the 2 mufflers to help with low end torque. Sounds like you may have ended up with a set like this. Have the muffler shop plug the hole for you with their wire feed welder, I'd use the upper one with the hole on the bottom for appearances sake if it was me. Max

Title: Re: Sportster Muff - OK, I'm a moron... Post by pgolden on 03/20/06 at 13:53:40 The 2003 and older sportster mufflers do not have the crossover fittings. Put those back on E-bay and get the right ones. If you use one of the ones you have the opening will have to be capped off or welded up. You might not be able to turn the "patch" down where it does not show depending on the mounting bracket.

Title: Re: Sportster Muff - OK, I'm a moron... Post by slavy on 03/20/06 at 14:15:29 Plug the hole. Usually the hole is from inside and You don't have to worry about the welded cap being visible.

Title: Re: Sportster Muff - OK, I'm a moron... Post by pgolden on 03/20/06 at 14:30:54 That "hole" is a 1 3/4" diameter, 2" long pipe fitting protruding out of the side of the muffler where the header pipe connects. I guess one of the mufflers would mount up with the fitting pointing down, but it might drag the pavement in a sharp turn. If you have the muffler shop cut the fitting flush and wire weld a patch in that would be OK. You might be able to buy another muffler cheaper than the labor to patch up the one you have.

Title: Re: Sportster Muff - OK, I'm a moron... Post by SeeAPierce on 03/20/06 at 18:10:39 I'm with pgolden:  better to upload those two to ebay and use the paypal money to buy a single sportster muff without the balance tube.  Cutting, welding, patching -- unless you have the tools to do it yourself will end up being more of a pain than starting with the other version of muff. pgolden wrote: That "hole" is a 1 3/4" diameter, 2" long pipe fitting protruding out of the side of the muffler where the header pipe connects. I guess one of the mufflers would mount up with the fitting pointing down, but it might drag the pavement in a sharp turn. If you have the muffler shop cut the fitting flush and wire weld a patch in that would be OK. You might be able to buy another muffler cheaper than the labor to patch up the one you have.

Title: Re: Sportster Muff - OK, I'm a moron... Post by Steve530 on 03/20/06 at 18:11:51 Yep the late model Sportsters have crossovers.  I agree with pgolden, just put it back on ebay and buy the earlier model muffler.

Title: Re: Sportster Muff - OK, I'm a moron... Post by pgolden on 03/21/06 at 06:37:10 Here are the item numbers on e-bay that will work: 4622148658 4622957658 4624334532 4621501670 4623922734 4623896384 These are the inexpensive ones.

Title: Re: Sportster Muff - OK, I'm a moron... Post by Capt._Capsize on 03/23/06 at 08:13:17 as already suggested, unload the muffs you have.  I would visit all the Vtwin repair shops and custom shops in your area.  Around here they are everywhere.  Muffs usually go for 15 to 25 bucks.

Title: Re: Sportster Muff - OK, I'm a moron... Post by theikeman on 03/23/06 at 21:12:40 I agree, re-sell those on ebay and get yourself a pair of Dyna Mufflers, there is NO tab to bend and the mount ligns up nicely with your stock bracket. Just make sure you get 2003 or older without the crossover pipe. You will be happy with the dynas. http://photos.imageevent.com/cars4auction/kwikbay/dyna1.jpg Ebay Item number: 4624996092

Title: Re: Sportster Muff - OK, I'm a moron... Post by mpescatori on 03/24/06 at 02:42:17 Caruso, you might have another option if you like wrenching around and fiddling and tweaking etc. ... You could use the muffler with the compensation tube pointing up, fit a long(er) pipe to it, and an adjustable piston, so that the length of this new pipe is variable. Then run the bike at different revs and see how she sounds and performs. This kind of contraption is a 'tunable resonance pipe', and helps to have low down grunt vs. high end screaming ???  horsepower. BTW Porsche did something along these lines for the earlier road-legal 911Turbos (the ones with the older, 4-on-the-floor) they had a ballasted trap door in the muffler so that when boost exceeded a certain limit, the exhaust would not be baffled but 'straight through' Lovely screamer from a flat 6 As they say in Kentucky, it's horses for courses. Maurizio PS OK OK stop horsing around, flog the muffs on eBay and get the other kind  ;)

Title: Re: Sportster Muff - OK, I'm a moron... Post by caruso81 on 04/01/06 at 15:17:15 Well, I did cut one of those crossover inlets off and ground it down. Turned out OK, but I went ahead and got the Sportster anyway. The first muffler was a little longer, and I didn't like the look, although I think it would have worked fine once I got the 1 3/4 tailpipe extension in there. The Sportster is on now, and aside from the bu-u-utt fugly muffler clamp, it looks, sounds, and runs perfectly....the sound really is like having a new bike. Very soft "whump" when I shut it off, but almost no backfire closing the throttle (152.5 jet, went one up on the pilot jet, full white spacer in). I have a KN filter, but I have to go get the 155 jet...it ran extremely lean with the KN in, so I went back to stock for now. Also have to figure out how that fu-u-ugly clamp is going to get along with a universal heat shield. BTW.... thanks for the ideas.

Title: Re: Sportster Muff - OK, I'm a moron... Post by Steve530 on 04/02/06 at 20:15:49 Did you get a HD muffler clamp?

Title: Re: Sportster Muff - OK, I'm a moron... Post by SeeAPierce on 04/03/06 at 06:07:55 Yea for fitment and looks the harley clamp is pretty good in this application...

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