SuzukiSavage.com - dyna muffler install holes not lining up right

MeLikeBike

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dyna muffler install holes not lining up right
06/16/13 at 19:59:52

Hi guys,
I'm putting on the dyna, but when I push the muffler as far as I can (it does not reach the raised lip on the headerpipe), the hole in the frame is lining up too close to the enlarged hole in the muffler bracket. So when I think I get everything lined up nice, then tighten the muffler bracket nut, it shifts a little then pulls the head of the bolt through the rail.

Did anyone else have to deal with this? I suppose I could drill another hold in the frame, but I don't wanna.

In other words:

bolt |'''''|
|_|

_______/''''''\______ Rail slot on muffler

'''''''\______/'''''''''''

''''''''''''''''''''''\
O | Frame
_____________________/

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2003 Savage LS650, Dyna, 2/3 Spacer

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28651 Tucson Az Gender:	Re: dyna muffler install holes not lining up right Reply #1 - 06/16/13 at 23:20:48 Digital cave paintings... Cool!... ... I had this problem recently,.. with a cat model... Drill a new hole in the bracket... ... don't have a drill?... hacksaw a bit off the head pipe... ... don't have a hacksaw?.. Buy some tools... ... When modding a bike,.. if it don't fit... make it fit... ...
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bobert_FSO

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Re: dyna muffler install holes not lining up right
Reply #2 - 06/17/13 at 05:36:34

I sawed off a small amount of the the header pipe so the muffler would reach the stop ring on the header.

Also, you could alternatively not shove the muffler on the header as far as it will go. Back the muffler off a little. As long as there is enough header/muffler overlap to get a good clamp and seal with a clamp, it should be good to go. Most exhaust systems do not have a built-in "stop" when being mated up.

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ToesNose Serious Thumper Offline Pardon me, do you have Hot Sauce? Posts: 1993 Mooresville, NC Gender:	Re: dyna muffler install holes not lining up right Reply #3 - 06/17/13 at 06:30:19 Yea I hate it when the holes don't line up. .
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Badass94Cad Senior Member Offline This space for rent Posts: 313 Mass-->Jerz-->PA! Gender:	Re: dyna muffler install holes not lining up right Reply #4 - 06/17/13 at 10:00:38 I affixed the Dyna muffler with only one of the two holes on the stock mounting bracket, the closest to the engine. Some people have adapters made that will also push the muffler further back, aligning it better on the bracket.
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apache snow-FSO Serious Thumper Offline Posts: 509 Gender:	Re: dyna muffler install holes not lining up right Reply #5 - 06/17/13 at 10:03:14 Yeah, using the Ryca adapter I use both bolts to hold down the muffler.
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Oldfeller--FSO Serious Thumper ModSquad Offline Hobby is now "concentrated neuropany" Posts: 12671 Fayetteville, NC Gender:	Re: dyna muffler install holes not lining up right Reply #6 - 06/17/13 at 10:07:14 BIG fender washers ....... bridge the gap.
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MeLikeBike

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Re: dyna muffler install holes not lining up right
Reply #7 - 06/18/13 at 19:36:14

I drilled a new hole, and things line up okay. I just can't stuff the exhaust leak that I have now. I've tried at least 8 times with different cans...ended up using some aluminum flashing cut in a strip and rolled a few times because those Harley clamps don't seem to tighten down enough. But still little leaks.

took it out for a ride..sounds great, when I push it and switch gears. I'm a little used to the quietness to the stock muff. Maybe a bit loud after a long ride, though.

I'm hoping the leak will fill with soot or something...but I can always goop it with some ultra copper. I have some of the high temp red from my engine head replacement...maybe the red is hi temp enough?

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2003 Savage LS650, Dyna, 2/3 Spacer

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: dyna muffler install holes not lining up right Reply #8 - 06/19/13 at 21:56:12 fficial&client=firefox-a" target="_blank">https://www.google.com/search?q=t+bolt+clamps&ie=utf-8&oe=utf-8&aq=t&rls=org.mozilla:en-USfficial&client=firefox-a
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MeLikeBike Junior Member Offline Newbie, but Goodie Posts: 59 Monroeville, PA Gender:	Re: dyna muffler install holes not lining up right Reply #9 - 06/20/13 at 17:22:53 I got the HD pipe clamps off ebay...I though that would do the trick. Are those Tbolt clamps any better?
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: dyna muffler install holes not lining up right Reply #10 - 06/20/13 at 21:35:01 Well,, I dunno,, What did ya pay for yours? Why arent they working? Do you need to slot something some so the clamp can Squeeze it? Be careful not to bump your head while squeezing,, seems to be a problem around here..
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MeLikeBike

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Re: dyna muffler install holes not lining up right
Reply #11 - 06/21/13 at 05:03:37

They aren't (weren't?) working because they couldn't seem to get tight enough, I guess. So I shimmed around the exhaust pipe AND around the muffler. And so I think it still leaks, but not enough to keep delaying me from riding it while the summer arrives with some beautiful weather here in Pittsburgh.

I *did* slot it with a dremel cutoff wheel (a little thinner than the hacksaw blades it seems, based on the hacksaw picks here at ss.com). At first, 4 extra slots, but now I have about 10 slots because there just wasn't enough squeezability.

The flashing that I used is plastic coated, at least a little, so it's melting and stinking nicely now, and I was able to tight down on the clamp a little more after riding last night (expansion of stuff + melting of the plastic stuff). So maybe between the further tightening and the melting plastic and the soot and all, it will seal itself more.

One thing about those HD clamps. With the tin can gaskets, once you tighten, if you monkey with it too much, the clamp will pinch the wrap into the clamp's joint, and thereby ruin your seal.

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2003 Savage LS650, Dyna, 2/3 Spacer

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MeLikeBike Junior Member Offline Newbie, but Goodie Posts: 59 Monroeville, PA Gender:	Re: dyna muffler install holes not lining up right Reply #12 - 06/21/13 at 08:01:12 btw, anyone buy this from Ebay? http://www.ebay.com/itm/Chrome-Exhaust-Muffler-Pipe-Heat-Shield-Cover-Heel-Gu... pretty generic, but probably fits the bill. Just not sure if it's as thin as tin foil or something.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: dyna muffler install holes not lining up right Reply #13 - 06/21/13 at 08:23:28 Check shipping weight. Send an email & ask them what it weighs,
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apache snow-FSO Serious Thumper Offline Posts: 509 Gender:	Re: dyna muffler install holes not lining up right Reply #14 - 06/21/13 at 08:42:29 No, I bought this one from motorcycle superstore in a 2x7. Its around the same thickness as automotive exhaust tubing, .062. http://www.motorcycle-superstore.com/3/13/118/31163/ITEM/Cobra-Universal-Heat...
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