SuzukiSavage.com - Muffler install

88pagan

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Muffler install
07/08/08 at 18:39:13

I've read as many topics as I could find on this but still having some trouble. Just received the screamin eagle muffler I purchased..it came with mounting instructions and a "shim" to make up the difference in the exhaust pipe and the header tube but it is still far from being a so-called easy install. I can't see anyway possible to make up that difference in the inside diameter of the new muffler and the outside diameter of the header pipe without some serious modification. I'm debating taking it to my local muffler shop and getting him to add some pipe to the header that will take the muffler easier. Anyone install one of these and have any luck getting it to seal on the factory pipe? Thanks in advance for any help

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96 Bobber - Screamin Eagle, header wrap, K+N cone filter, jetted, straight bar w/1.5" risers, solo seat, Ed. L fwd ctrls, custom rear fender, TKat, Metallic charcoal and polished all over.

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Educatedredneck

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Re: Muffler install
Reply #1 - 07/08/08 at 22:49:00

Follow your instincts, take the muffler and the head pipe to your local muffler shop - that is what I did, cost me $10.00 bucks to get a 6" piece of pipe made to fit the head pipe and my dyna muffler. Two clamps (or have it welded) and your all set. REMEMBER to re-jet your carb ASAP!!!! BTW my extension pipe if you will was 1.75" ID/OD approx.

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1997 Savage - Hard Chrome Drag Pipe, Seat Mod, 152.5 main, 1 - #4 washer, Di Hard Battery, T-Kat, 1" Drag Bar

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T Mack 1 - FSO

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sold 2001 LS650 for
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Re: Muffler install
Reply #2 - 07/09/08 at 06:18:32

88pagan wrote on 07/08/08 at 18:39:13:

I've read as many topics as I could find on this but still having some trouble. Just received the screamin eagle muffler I purchased..it came with mounting instructions and a "shim" to make up the difference in the exhaust pipe and the header tube but it is still far from being a so-called easy install. I can't see anyway possible to make up that difference in the inside diameter of the new muffler and the outside diameter of the header pipe without some serious modification. I'm debating taking it to my local muffler shop and getting him to add some pipe to the header that will take the muffler easier. Anyone install one of these and have any luck getting it to seal on the factory pipe? Thanks in advance for any help

What model muffler???? The HD Dyna's I've had in hand (6 to date) all needed just a thin piece of metal to make up the diameter diff. The Dyna fits a 1 3/4 inch pipe. The LS650/S40 header is just under that.

I did find that the inner pipe on my header fits in a 1 3/4" pipe I picked up at Auto-Zone , but the A-Z pipe didn't fit over the outer header at all.

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Engineers design things, Technicians make them work.
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thumperclone Serious Thumper Alliance Member Offline PGR rider riding with respect Posts: 6051 Grand Junction Colorado Gender:	Re: Muffler install Reply #3 - 07/09/08 at 08:01:58 in the past have used cut up beer can,plummers strap,and rtv sealant.. had midas make me a piece with a 6 deg bend to keep gasses off rear brake...$5
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88pagan

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Re: Muffler install
Reply #4 - 07/11/08 at 08:56:59

Thanks for all the info. I ended up hitting up a muffler shop and had an extension welded on...seals up perfectly. Wish I would have thought putting a slight bend in it as you stated but I was able to bend the extension enough to get it away from the brake. Now I just have to decide if this screamin eagle is loud enough that I'm going to get hassled by the man!

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96 Bobber - Screamin Eagle, header wrap, K+N cone filter, jetted, straight bar w/1.5" risers, solo seat, Ed. L fwd ctrls, custom rear fender, TKat, Metallic charcoal and polished all over.

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northshore_paul

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Re: Muffler install
Reply #5 - 07/12/08 at 15:56:51

To those that have used the Dyna mufflers, I have a few questions.

1. Where does the muffler bracket fall on the bike's muffler bracket and does it lay flat against it or does it have a gap on one end?
2. What kind of clamp did you use to tighten the muffler on to the header pipe extension?
3 Has anyone used the stock heat shield to cover the joint between the muffler and exhaust header?

Thanks in advance for your replies, Paul

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Gort

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Re: Muffler install
Reply #6 - 07/12/08 at 16:38:36

On my '96, the Dyna muffler bracket bolts flat to the Savage bracket without modification. The muffler slides onto the Savage header pipe to within 5/16ths of the header pipe collar, and stops. The muffler clamps to the header pipe with the Harley clamp that came with it. The Savage heat shield bolts on as usual, and covers the muffler connection. There are no leaks and it never came loose.

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northshore_paul Junior Member Offline Keep it simple....less to break! Posts: 68 South Louisiana Gender:	Re: Muffler install Reply #7 - 07/12/08 at 16:51:42 Does it mount flat with 2 bolts or does it not go back far enough and you only use 1 bolt?
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Gort Ex Member	Re: Muffler install Reply #8 - 07/12/08 at 17:57:44 northshore_paul wrote on 07/12/08 at 16:51:42: Does it mount flat with 2 bolts or does it not go back far enough and you only use 1 bolt? Mine mounts flat with 2 bolts. Its almost as if the brackets were designed to fit together, which is quite a coincidence.
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T Mack 1 - FSO Serious Thumper Alliance Member Offline sold 2001 LS650 for a 1986 XLH1100 Posts: 2919 Emmaus,Pa Gender:	Re: Muffler install Reply #9 - 07/12/08 at 19:20:25 I have a close - up's in my muffler post. Ain't whistling dixie.. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1190410150
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Gort

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Re: Muffler install
Reply #10 - 07/12/08 at 21:18:40

T Mack 1 - FSO wrote on 07/12/08 at 19:20:25:

I have a close - up's in my muffler post. Ain't whistling dixie..

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1190410150

This pic tells me there must be many variations of the Harley Dyna muffler. Mine looks nothing like the one in your pic. Perhaps this is why this site gets so many posts having to do with problems installing the Dyna.

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FreeSpirit

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North Georgia
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Re: Muffler install
Reply #11 - 07/12/08 at 21:51:15

Arthur wrote on 07/12/08 at 21:18:40:

T Mack 1 - FSO wrote on 07/12/08 at 19:20:25:

I have a close - up's in my muffler post. Ain't whistling dixie..

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1190410150

This pic tells me there must be many variations of the Harley Dyna muffler. Mine looks nothing like the one in your pic. Perhaps this is why this site gets so many posts having to do with problems installing the Dyna.

TMack's looks different than the ones I've seen too.(I like the looks of his though)
You might be right on the installation Undecided

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2002 Suzuki Savage-Stock.Windshield,Saddle bags,Hwy Bars,Tank Bib.Custom Paint.

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T Mack 1 - FSO

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Re: Muffler install
Reply #12 - 07/13/08 at 11:24:15

Mine isn't a Dyna stock take-off It's a aftermarket "Screaming Eagle" clone.

Here's the link to the 4 take-off's I sold, am selling (Cory has dibs on the last one). They are much more quite then the SE clone. They all fit the same. One has the bracket offset different so mount needs a plate.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1214181474

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Engineers design things, Technicians make them work.
---
30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

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Staplebox

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CT
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Re: Muffler install
Reply #13 - 07/13/08 at 13:57:14

I recently put on a Dyna that looks like the ones pictured above. The bracket only lines up with one hole, the front, on my bikes frame. And it does not lay perfectly flat inside the bikes bracket, but almost. I sprng for a new SS bolt, washer, lock washers and nut. Didn't want it to fall off.

It also does not slide all the way up the header pipe. I made a Bud Light shim and used some Permatex to seal the connection.

I also used a HD clamp that came with it.

I didn't put the stock heat shield back on, it just didn't look right to me. I am going to get one of the $20 generic ones from JC W when I think of it.

I'd recommend the mod. Sounds better, moves better and, after some carb tweeking, I am still averaging 51 mpg.

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