Gort
Ex Member
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SJ you are close but not quite there yet. I ran into the same problem of the header pipe being a tight fit. I got to where you are, and seeing the problem, made sure the muffler bracket was lined up with the Savage bracket, and then used a Magic Marker to make locater marks on the mouth of the Dyna muffler in relation to the the Savage pipe. I then removed the Header pipe from the Savage, and placed both it and the muffler on the work bench. Carefully bracing the header pipe from moving or bending, I re-aligned the muffler in relation to the pipe, using my locater marks. Then, using a piece of 2X4 behind the muffer's rear exhaust outlet, I hit the 2X4 with a hammer, driving the muffler onto the header pipe ( using Pepsi can aluminum as a shim around the header pipe.). I kept checking the alignment of my marks, and watched to be sure that the muffler inlet went over the header pipe in a straight manner. I was able to tap the muffler onto the header pipe until the header pipe shoulder was within 5/16" of the muffler mouth. I then clamped it tight with the Harley clamp that came with the Dyna. Then I very loosely bolted the assembly back onto the bike, first to the Savage bracket. I then bolted the header pipe back to the engine firmly. I then tightened the muffler to the Savage bracket, and then put on the heat shield.
It may be that part of the reason some members need to use spacers between the Savage frame bracket and the Dyna; or tweak one of brackets; is because of minor variances in the bracket locations from one frame to the next. Remember, this bike frame is no precision item. You're not dealing with a wristwatch here. There may well be minor variations from one frame to another, in any low end assembly line product, like this one.
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