I have a sportster muffler...actually I have two.   I am getting ready to put it on my wife's bike but am not too sure how I am to do it.

I looked at the Sportster Muffler Thread (http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1114360126) but the pics are all missing (and I REALLY like pics)

Couldn't quite picture some of the stuff that was being said.

The mufflers have a tab on it.  From what I gather the tab has to be hammered back.  Which way?  If the connector end was on the right.  Do you bend it towards or away from you?  And how much... 90 degrees?

So is this bent tab able to bolt onto the stock support arm?

Does the muffler go directly into the header pipe or is their an intermediate piece needed?

I have seen (on ebay) that there are people selling reducer sleeves to go from one pipe to the other..is it required?  Or do you just clamp like crazy?

ANY other hints, advice, anything would be greatly appreciated.  My wife thinks I am gonna make a mess..she's probably right  

ok, you're gonna have to measure the inlet on the sporty muff... if it's 1 1/2 inch id it's a bolt-on... if it's 1 3/4, you need an adaptor...you can buy the one on ebay, go to a custom shop, get 1 from an exhaust and muffler shop, or cut up a can.... if you cut a can, you have to use a good tailpipe sealer, not a muffler patch(the sealer is a good idea either way)... before you mount it with the adaptor, dry fit it... check how the mount tab lines up with the bike's bracket... does it? you may need to drill a hole, you may need to bend the tab, you may even need to add a small bar between them....  all depends on year and size of the bike the muff came off of... it sounds much more complex than it is, you'll see once you get started... ok, now dry fit the adaptor into the muff... did it go in pretty easy? if so, you're ready to go, if not, another trip to the muffler shop to get the muffs opening expanded.... make sure to use a harley clamp.... ok, everything gathered on the starboard side of your bike, you slick a little sealer inside the adaptor, then shove it onto the headpipe(may have to tap with a piece of wood, or a rubber mallet)...put the clamp on the muff or headpipe all loose, jus t so you can slide it into place, now slide the muff on(a little sealer inside the muff, and outside the adaptor), just making sure the mount tab is reasonably close to aligned, now, get your mounting setup lined up (tap, twist, shake, beg, curse, etc)and get the mounting hardware loosely installed... now tighten down your clamp(might be a good time to make sure the headpipe is secure to the head as well), finish tighten the hanger hardware, apologize to the bike for cursing at it, and start her up and check for exhaust leaks.... rejetting may be required, or just an adjustment of the airscrew depending on how "open" the muff is.... then, the "victory lap"..... easy wasnt it?

I clamped like crazy with an automotive exhaust muffler clamp. I then buttered around the seam with exhaust sealer and finally covered it all by cutting a longways slit in a 6 inch chrome sink drain tailpiece ($2.50 at hardware store) and clamping that over the auto clamp.

White Spacer Mod and Idle Mixture Srew Mod was necessary to cure backfiring/popping. Runs / Sounds Great!

I also just used a piece of a 1/4" x 3/4" flat steel brace with holes pre-drilled to bolt muff on to stock muff hanger with a bolt, lock washer & and nut. No bending of the Sporty's tab necessary.

(P.S. I have pics but can't post them now with work computer's security software running.)

I just fit my 1200 sporty muff directly over the header pipe and clamped it down good with a 1 3/4 exhaust u-bolt clamp.  It works decent but it doesnt make a perfect seal and I get some popping and snapping on rapid decel, but its nothing that really bothers me or hinders performance.  A re-jet and intake mod were needed along with idle mix screw to accommodate the new muffler.  I do plan to try and seal up the union of the header and muff better after I move at the end of the month and get settled.

-P.S.  Would header wrap work as a decent sealer between the muff and header?  I have some left over and if it wont work then I'll try the aluminum can and high-temp copper silicone sealant idea.

-Matt

matt_savage wrote on 05/14/09 at 07:26:16:

go to a real auto parts store (not walmart, pepboys, or target), and get exhaust pipe sealer(not muffler patch, or repair tape)... go to your local muffler shop, and ask the guy doing weld-ups what brand he uses(he just might toss you the tailend of a tube, as well)... it's a grey ceramic slurry in a toothpaste tube... ever wonder how the shop kept that pipe joint with 2 tackwelds and no clamp from leaking? it's probably all made by the same company, just different local names for the brand (like indian head gasket shellac, which ive seen marketted under at least 5 names through the years) for high temps and medium pressures, this stuff is incredible!!  and just like bril-creme, a little dab'll do ya...

THANKS for all the input!

An extremely helpful forum this is.

I am going to see if I can do a dry run and get a better idea of what is needed.

Maybe I can find time this weekend.

Yonuh Adisi FSO wrote on 05/14/09 at 14:03:44:



I was looking at Flightsimshop as he seemed to sell a lot of Savage stuff... but it is noted.  Thanks.