The later model Harley mufflers have a crossover tube (which connects the two mufflers) and should be avoided. Any Harley muffler will fit on your Savage with just a little work. If you add a freer flowing muffler, you should definately rejet your carb to get more fuel to the engine. You don't want to run too lean - it's not good for your engine.

I think a stock Harley muffler will give you the better sound you are wanting.

Dear BonnieCC:  I too have an 06 s 40 and just recently put on a Harley Sporster muffler and did the rejetting.   I had to search for mine but finally found it from one of those fly by night motorcycle shops--they had one lying around and sold it for cheap.   Go to  Topic: Sportster muff installation  (Read 3995 times) under Technical Documents forum.  That has detailed instructions on how to get the muffler on.  Here is a picture of mine: http://w2.bikepics.com/pics/2007/03/27/bikepics-843565-full.jpg

It sounds deeper and is only a bit louder.  It didn't run very well until I did the carb modifications but ran ok with just the spacer modification.  I bought the dynojet rejetting kit b.c. it has all the intructions there and did that and now it runs awesome, no backfiring, and cruises at speeds more than acceptable for interstate and highway use.

Do you want to do the mods yourself or get your mechanic to do them?  They do take a lot of work (finding the right parts too) and concentration but I really enjoyed them.  I also must say there is some risk involved, in that its possible to get yourself into some problems and then you have to think how to solve them. The carb parts are small and delicate and require care in getting them off (those pesky brass screws) and on again.  My wife and 3 year old got a bit annoyed with all the time I spent with the bike but now it is a far superior machine and I am much happier with it--you realize how inferior the stock one really is.  I am saying this as a Newbie who never worked on a motorcycle before getting my s-40 Savage and its great to be able to work on it as well as ride it.

I think that the white spacer modification solves the backfiring for the most part but  you also might have to adjust the fuel/air screw (involves drilling out a plug) a bit to get it just right.  The main jet is underneath the carb (that took me a while to figure out) but you get to the white spacer from the top.

Thanks to the guys on this website for their great advice and instructions.  I am sure the future will bring me back asking for help!    

I recently put a Harley Dyna muffler on my '06 S40. A friend of mine bought a brand new Dyna and had Screaming Eagle mufflers put on it before he even picked it up. The Dyna mufflers had no crossover pipe to deal with. If your dealer has 883 mufflers he probably will have Dyna mufflers. Basically a bolt on fit. I have tried mine without the factory muffler to head pipe gasket but I can not keep it sealed tight. Next rainy Saturday it's coming back off. I was in to big a hurry to take the 30 minutes to do it right the first time. You can take it to an AutoZone, or if your dealer does the work, use the loaner pipe expander tool to expand the muffler connection enough to be able to get the headpipe, gasket and muffler hooked together. I recommend the Harley muffler clamps. They are wider and stronger than the factory clamp and look better than an automotive type clamp. You will read in the post here on the muffler mods that an extension is needed to keep the exhaust off the rear brake rod. I accidentally bent the muffler bracket and realized how soft it was. I mounted the muffler to the headpipe, hooked the headpipe to the exhaust port and torqued it, made the final adjustments to the muffler to get the mount bolts lined up with the bracket, and then bent the bracket to fit. You will love the sound, slightly louder but with a deeper tone.  Did the carb mods at the same time with a K&N drop in filter. I am still getting 60 MPG commuting 30 miles each way to work. Sorry for the rambling on but when I get started I can't stop. This forum has been an outstanding source of info. I am a returning rider after 25 + years (didn't ride much then). Good luck and enjoy your ride.

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


Much? Any would not be good. A rejet will be better.

Hi Bonnie
Welcome to the site.

Go back about 5 pages and find "Question on Exhaust Modification"

I installed a rail mount HD turnout on my 96 and have only adjusted the idle mix screw. (under the brass plug on rt side of carb) There are some pics of several muffler conversions including mine. No more shotgun blast backfires, sometimes a little popping on shifts and only an occasional "Chuff" type sound when turning off the engine. It's not REAL loud, but I have heard occasional car alarms going off as I pass by.

BTW I'm 60 yr old Musician/Vacuum Tube Amp Technician

Thanks Bonnie
Good to meet fellow musicians.
Yes, I really love my 96, commute every day, joy ride on weekends too.
I did pick up some jets and got a few from Lancer too, will try to experiment, but I hate to take it apart if there is a chance to ride instead.

Happy Trails Bonnie
p.s. check out my Irish band (see site at bottom of this post)

Thanks Rob. I will try the searches.  I have already found great advice.  The knowledge base here is incredible.  
Bonnie