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Sportster muff installation (Read 1503 times)
bobo383
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Sportster muff installation
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:



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.



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











Now to cover up the ugly car muff clamp:



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





Photos are on my photobucket page if you want them:
http://photobucket.com/albums/y114/bobo383/?multi=9&addtype=
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« Last Edit: 12/03/12 at 01:08:11 by Oldfeller »  

Arlington Texas
Used to have 98 & 88 Savages
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Nightrain
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Re: Sportster muff installation
Reply #1 - 04/25/05 at 16:37:53
 
These directions are the balls  Grin ....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  Smiley
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bobo383
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Re: Sportster muff installation
Reply #2 - 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.
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SavageRider
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Re: Sportster muff installation
Reply #3 - 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
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bobo383
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Re: Sportster muff installation
Reply #4 - 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.
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SavageRider
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Re: Sportster muff installation
Reply #5 - 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 Smiley.

SavageRider
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savagethumper
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Re: Sportster muff installation
Reply #6 - 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.
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bobo383
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Re: Sportster muff installation
Reply #7 - 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.
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bobo383
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Re: Sportster muff installation
Reply #8 - 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.



I got a pair, so the other one will be selling shortly.
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Hammy211
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Re: Sportster muff installation
Reply #9 - 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.
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bobo383
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Re: Sportster muff installation
Reply #10 - 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:  

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.
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Hammy211
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Re: Sportster muff installation
Reply #11 - 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?
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bobo383
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Re: Sportster muff installation
Reply #12 - 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.
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LANCER
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Re: Sportster muff installation
Reply #13 - 06/14/05 at 07:39:11
 
bobo383 wrote on 12/31/69 at 16:00:06:
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.
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Hammy211
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Re: Sportster muff installation
Reply #14 - 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.
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