I recently got a dyna, thanks kit, and tore off my stock muffler last night and am trying to get the dyna to seat correctly.  I searched for a post on how to install the dyna, but couldn't find much that was useful (this could be because I am either terrible at searching or the search engine sucks).  Can someone either refer me to a post on this with pictures preferably, or post up some information on what I should do to make it seat properly?  Basically, what did you use to cover the area where the muffler joins the header pipe?  Did you just use the clamp that was on the bike to secure, or buy something else to use?  Did you have a 1/2 space that you couldn't get the dyna to cover on the flanged part of the header pipe?    I can post picture later tonight if my question don't make sense.  I am doing the seat mod, dyna and turn signals tonight.  Should be fun.  I already have the dyna most of the way on.

FYI - This post should probably be in RSD.

dmike wrote on 08/18/09 at 07:31:55:

Here's a bunch of random pictures I took when doing this: Muffler Pictures

dmike wrote on 08/18/09 at 07:31:55:

COBRA HEAT SHIELD 2" 99-0165P
They have different lengths.

dmike wrote on 08/18/09 at 07:31:55:

Harley clamp.

dmike wrote on 08/18/09 at 07:31:55:

Yes.

In the end I went with an adapter. See pics.

-D. Dwarf

twdy wrote on 08/18/09 at 07:41:40:


My mounts will fit with about 1/4" to spare.  If the dyna had set studs to mount from it wouldn't have worked.

Drunken Dwarf - Those pictures help a lot as well as all the other information you posted.  I didn't have a harley clamp on the pipe.  There is a clamp from the s40 I can use in the meantime until I get a larger one.  I didn't hear a leak last night when I started it up with the muffler not even clamped on, so I think I should be okay without an adapter, what do you think?  I have the same white S40, what year is yours?

Prechermike - Thanks for posting that, your heat shield really makes it look great.  I wasn't going to weld it incase I want to put a different pipe on later, but the sound seemed like what I was looking for so I might do what you did.  Is your heat sheild the same as the one drunkendwarf listed above?

Thanks all, this will hopefully go real easy now that I have this knowledge.

dmike wrote on 08/18/09 at 08:55:46:


Nope, mine is the heat sheild that came off of the Harley, or at least part of it.  My buddy had changed his mufflers and had the whole thing laying around, told me to get what I needed, which I gratefully did.  The shield started out looking more like a "Y", but I made it fit.

For a shim, I used some aluminum flashing from leftovers from the roof cut with tin snips. But, I'm more of a country guy than a "do it perfectly" guy.

I got the Dyna on, ordered the heat shield from Amazon, and am extremly happy with the set up.  I first tried to attach the Dyna without taking the header off.  We took off the one bolt behind the muffler/header union area and tilted the muffler brace down and then slipped the muffler on the header and then worked like a bugger to get the bolts into the muffler brace area.  We did but found that the dyna rubbed the brake cable.  Took the muffler back off and then took the header off.  Put a 4 washer spacer between the muffler and the muffler brace so it wouldn't rub the cable any longer.  Re-attached everything and there were some back fires and a leak between on the dyna where the dyna has a space to expand at the collar where it attaches to the header.  Oh and I am using a HD clamp, 7.50 at the harley shop.  Put a piece of aluminum flashing, thanks Sakara, between the HD clamp and the muffler hoping it would fix it.  Well it still leaked but we quit there anyways.  I drove it to work today, no backfires, only a "poof" when I turned it off, and it sounds great!  I am pretty sure I don't have a spacer in because the last time I took it into the shop for service I am pretty sure they told me they took it out to help fix the backfire problem.  Oh I also turn up the idle screw too, not sure how high but I think that fixed a lot of the back firing since after I got the muffler on it was popping and backfirign a lot, and now . . . nothing.

I'll get pictures once I have the heat shield to put on.  

Thanks everyone for the help.