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Message started by bobo383 on 04/24/05 at 09:28:46

Title: Sportster muff installation
Post by bobo383 on 04/24/05 at 09:28:46

Contacted 12-3-12

My stock muff is gone already, so I can't detail the stock muff removal; but here's the details of my Sportster muff install.  

In addition to a Sportster muffler, you'll also need a few little pieces of hardware:

http://i4.photobucket.com/albums/y114/bobo383/sportstermuffparts.jpg

I put the sportster muffler on the carpet and bent the mounting tab over with a 3-pound hammer.  The sportster muff inlet is a little too big, but I brute forced a good seal with the car muff clamp.

http://i4.photobucket.com/albums/y114/bobo383/sportstermuff01.jpg

The Savage and HD mounting holes don't line up at all, so I had to make a new hole:

http://i4.photobucket.com/albums/y114/bobo383/Sportstermuff02.jpg

http://i4.photobucket.com/albums/y114/bobo383/sportstermuff03.jpg

http://i4.photobucket.com/albums/y114/bobo383/sportstermuff04.jpg

http://i4.photobucket.com/albums/y114/bobo383/sportstermuff05.jpg

http://i4.photobucket.com/albums/y114/bobo383/sportstermuff06.jpg

Now to cover up the ugly car muff clamp:

http://i4.photobucket.com/albums/y114/bobo383/sportstermuff07.jpg

Place bike in front of 64 Impala, but don't clean up the trash behind the bike.

http://i4.photobucket.com/albums/y114/bobo383/sportstermuffSide.jpg

http://i4.photobucket.com/albums/y114/bobo383/sportstermuffRear.jpg

Photos are on my photobucket page if you want them:
http://photobucket.com/albums/y114/bobo383/?multi=9&addtype=

Title: Re: Sportster muff installation
Post by Nightrain on 04/25/05 at 16:37:53

These directions are the balls  ;D ....One quick thing... Did the sporty muff have a gasket in it or did you pull the gasket out of the savage muff or did you buy a new gasket? thanks for all the time and effort and putting this together. I may just install that sporty muff afterall  :)

Title: Re: Sportster muff installation
Post by bobo383 on 04/25/05 at 18:57:33

No gaskets at all.  I did not find any gaskets in either muffler, so I just brute-forced the automotive clamp to make a seal.  Thanks for the kind words.  I really love wrenching on stuff.

Title: Re: Sportster muff installation
Post by SavageRider on 05/09/05 at 07:34:40

Bobo

How did you like the sound provided by the sportster muffler? Is it more mello than the stock Suzuki one?

Thanks
SavageRider

Title: Re: Sportster muff installation
Post by bobo383 on 05/09/05 at 19:02:49

Sportster muff has a lower tone than the stock pipe, and a little louder but not much.  I like it better.  I have a pair of Screaming Eagles coming from eBay, I'll let you know how one of those works out.  They sound killer on my neighbor's Sportster, so I have high hopes.

Title: Re: Sportster muff installation
Post by SavageRider on 05/12/05 at 13:58:53

Bobo

You are the champ when it comes to info. I like how you try out everthing and then share the data. Makes it much cheaper for everyone :).

SavageRider

Title: Re: Sportster muff installation
Post by savagethumper on 05/17/05 at 18:46:18

Bobo, you are definitely an interesting guy.  I could live in your garage.  I've seen hardware stores with less tools.   And bike shops with less bikes.  You did a great job putting the HD pipe on my bike.  I love the low sound, I think it is a much richer sound than the Jardine.http://i4.photobucket.com/albums/y111/savagethumper/newfatty2.jpg

Title: Re: Sportster muff installation
Post by bobo383 on 05/17/05 at 19:52:57

Very kind of you to say, thank you.  I like the Jardine, but I just got a Screamin' Eagle pair in the UPS from eBay.  I put one on tonight, real quick (not perfect), and tried it out.  VERY LOUD, but also very low tone and a poppy backfiring 60 mph in 2nd gear.  I'm going to seal up the leaks tomorrow, finish securing the muff to the bike, and check it out for a few days, and see if I like it.  The bike's running lean again, so the flow must be increased.  Time to put on the Amal from Lancer and let the Savage rip!  

I may wind up going back to the Jardine for (relative) silence - which is saying something, you know how loud the Jardine is!

The SE is very stout - takes way more hammer work to coerce the metal bracket and flange than any other pipe so far.  My arm hurts...OLD AGE.

Title: Re: Sportster muff installation
Post by bobo383 on 05/18/05 at 16:50:27

Here it is, the finished Screamin' Eagle install - BEST SOUND OF ANY MUFFLER I'VE TRIED SO FAR!

Bolts up like the stock sporty muff, but it's alot tougher to work the steel around.

http://i4.photobucket.com/albums/y114/bobo383/pict0004.jpg

I got a pair, so the other one will be selling shortly.


Title: Re: Sportster muff installation
Post by Hammy211 on 06/01/05 at 11:24:59

I will recieve my screamin eagle mufflers this Friday.  I would like to install them without the stock heat guard.  Any tips on how to make this a clean install?  I only ask b/c I would like to do this as quickly as possible so I would like to figure out what I need to do before Friday evening.

Title: Re: Sportster muff installation
Post by bobo383 on 06/01/05 at 18:45:11

That bottom pic of my black Savage is without any heatshield at all.  You can get a band-type muffler clamp from the auto parts store, looks better but it's not real strong.  You can also get a straight chrome heatshield/guard from JC Whitney,   It looks like Savagethumper's pic right here:  
http://i4.photobucket.com/albums/y111/savagethumper/newfatty2.jpg
I just got one of those straight shields to cover up where I welded the Screamin'Eagle on my header pipe to eliminate leaks for good.  The SE is real tough - much tougher steel than the stock sportymuff.  I guess you could say I like the Screamin'Eagle.

Title: Re: Sportster muff installation
Post by Hammy211 on 06/02/05 at 02:29:41

Thanks for the tip on the guard.  Should have thought of that.  I think I will do that with the clamp as shown above.  Are you saying that I will have leak problems?  I remember seeing somewhere that using part of a pop can as a shim helps the fit a little.  

Did you have to take the header off to weld the muffler?  

Title: Re: Sportster muff installation
Post by bobo383 on 06/02/05 at 14:58:53

I did not have leaks on the original sportster muff, but did have some with the SE.  You can make a shim/spacer, but I like it so much I went ahead and welded it to eliminate leaks for good.

I DID take the entire pipe off to weld it.  i clamped the muff in place with the pipe on the bike, then took it off and welded it up.

It would be a good idea to get an exhaust gasket (between head and header) if you are going to remove the pipe.  Mine was trashed, and I had to get another from bikebandit.  That was where most of my leakage was coming from, but I did not know that prior to removing the pipe for welding.

Title: Re: Sportster muff installation
Post by lancer on 06/14/05 at 07:39:11


bobo383 wrote:
I did not have leaks on the original sportster muff, but did have some with the SE.  You can make a shim/spacer, but I like it so much I went ahead and welded it to eliminate leaks for good.

I DID take the entire pipe off to weld it.  i clamped the muff in place with the pipe on the bike, then took it off and welded it up.

It would be a good idea to get an exhaust gasket (between head and header) if you are going to remove the pipe.  Mine was trashed, and I had to get another from bikebandit.  That was where most of my leakage was coming from, but I did not know that prior to removing the pipe for welding.


I just put one of the slashcut Screaming Eagles on my bike this past week (see pic on "mountain ride" post).  When doing it I used a small piece of exhaust wrap material as a gasket when sliding the muffler on the header, then clamped it down.  It made a perfect seal and was a very cheap fix to avoid any air leaks.


Title: Re: Sportster muff installation
Post by Hammy211 on 06/14/05 at 11:34:12

I recently installed a SE pipe on my bike.  I did not alter the muffler in any way.  bent the muffler mount a little an drilled a couple of holes.  Used a 1 3/4 muffler clamp and a bit of pop can for a tighter fit.  It's not super pretty it you lay down and examine how I did it, but it works and that was whats important to me.  So, just make it fit.  If you can get it on the header and attach it to the mount somehow you should be good to go.  

I think you will need to rejet.  Might as well get a K&N while your at it.  You will probably need either a 155 or 157.5 main.  Possibly a new pilot and you will need to shave down the white spacer considerably.  BTW, I found my carb mod and installation much more a pain that the muffler.  Be careful with those screws!

You will not be disappointed with the sound when you are done.  Bike drive MUCH nicer as well.

Title: Re: Sportster muff installation
Post by Hammy211 on 06/15/05 at 01:12:26

I bent the muffler mount simply buy pulling on it.  Only did it because I was in a rush to get it on and I knew I was going to have my hands full trying to bend the bracket on the muffler.  You need a Clymer manuel to help you with the carb assembly and disassembly.  I think you would hurt the bike if you didn't rejet and lower the needle.  It would be pretty obvious though by the backfires.  There is lots of stuff on this site about rejetting if you search.  You just need to make the muffler work.


lcs151 wrote:
exactly how did you "bend" the muffler mount? what do you recommend i buy to rejet? Amals? dynojet? which is better? what size do i need of each? anything else i need? what is a pilot? if i put these pipes on without re-jetting, will i hurt the bike? or should i rejet first?



Title: Re: Sportster muff installation
Post by pgolden on 05/09/06 at 07:02:11

USA model, pre-2004, does not matter about front or back. The difference in front and back is the mounting tab. You can rotate either muffler so the tab will be close to the mounting bracket. I would take the header pipe off the bike, carry the muffler and pipe to a muffler shop and tell them you need a 6 or 7 inch adapter with a 10 degree bend. That will be about $10.00 or $15.00.
When you use the adapter pipe the install is much easier and looks great. I have a picture of the adapter on bikepics. (see link in my signature line)

Title: Re: Sportster muff installation
Post by Targett3997 on 06/09/09 at 07:45:09

Does anyone worry about the exhaust blowing on the brake line?  It concerns me, and the only fix I see is to shorten the pipe and put some sort of deflector on it.  Any thoughts?

Title: Re: Sportster muff installation
Post by John_D on 06/09/09 at 14:45:18

Most people who are concerned put in an angled adapter.  That's what I did.  It both angled the pipe to match the swingarm, and extended it past the rear brake lever.

Those that don't go this route report that all it does is soot up the rear brake arm, resulting in the need to wipe it down once in a while.

http://i626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/IM000264.jpg
http://i626.photobucket.com/albums/tt347/redneck72102/Bike%20Pics/Bike%20Mods/IM000262.jpg

Title: Re: Sportster muff installation
Post by Struch on 11/15/15 at 11:18:47

Thanks your directions helpt allot! My muff was cut out with torch by previous ouner ((( I got sportster used muff for 30$ and this is all that I spend )

Title: Re: Sportster muff installation
Post by Pratik Tailor on 03/23/18 at 14:18:33

Hello Everyone, Is there anybody who provide me that adaptor with bent, because I went to muffler store and that person is telling me $80 for making that adaptor.

Title: Re: Sportster muff installation
Post by IslandRoad on 04/01/18 at 02:34:31

I had an 'adapter' made at a local exhaust shop. It extended the exhaust more than I liked, and I couldn't get it sealed. Luckily, the guy didn't charge me, because the project didn't work (he's a good guy!). In the end I stuck the Dyna muff straight on the header (with a home-made gasket) and used one bolt (and Loktite) to attach to the muffler mount on the bike. 12 months and she runs fine, and looks good to me ... I had to rotate the header pipe away from the bike a little bit, which bugged me. However, given the random compliments I get in the street, about the bike, I'd say nobody notices!

Title: Re: Sportster muff installation
Post by IslandRoad on 04/01/18 at 02:35:39

... my brake actuator gets sooted up, but that doesn't affect anythng.

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