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

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

Plug the hole. Usually the hole is from inside and You don't have to worry about the welded cap being visible.

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 on 12/31/69 at 16:00:03:

Here are the item numbers on e-bay that will work:
4622148658
4622957658
4624334532
4621501670
4623922734
4623896384
These are the inexpensive ones.

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.


Ebay Item number: 4624996092

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.

Yea for fitment and looks the harley clamp is pretty good in this application...