SuzukiSavage.com - So I did the Dyna exhaust

old_rider

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So I did the Dyna exhaust
09/27/13 at 23:00:38

and can't seem to get it to fit. It is about 3/4's to 1 " short and won't go all the way up to the raised knurl or what ever you call it. I used an old tin bean can for a gasket, but can't seem to get the muffler to go all the way against the stop.
Dang thing keeps leaking even after I went to Harley and got the clamp they use to hold the pipes on. So I guess tomorrow (sat) I will go get me some muffler tape to make up the difference to keep it from leaking. I'm not going to cut the exhaust manifold, seems like that would be defeating the purpose.
I'll post some pics tomorrow, dang thing is drivin' me nutz Angry

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bobert_FSO

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Re: So I did the Dyna exhaust
Reply #1 - 09/28/13 at 05:39:50

Not slipping on all the way to the raised stop is OK. It goes on far enough to clamp and seal. If it looks too ugly, you can buy a small shield to put over the joint.

Yes, you usually need to shim between the header and muffler with some tin can or sealing tape as you mentioned. The header pipe is slightly smaller than the 1-3/4 inches that the muffler is and that gap needs to be filled. I successfully used some sheet asbestos that I had laying around. Also a full circle clamp helps. I'm not sure what the harley clamp looks like.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28666 Tucson Az Gender:	Re: So I did the Dyna exhaust Reply #2 - 09/28/13 at 09:28:49 Muffler tape is a waste... it'll fall apart.. Buy some lead sealer tape... it's used for sealing wood stoves... Wrap it round the pipe, and crush the muffler to it... If that won't seal it... nuttin' will... ...
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old_rider

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Re: So I did the Dyna exhaust
Reply #3 - 10/03/13 at 14:50:32

Managed to get it to seal with maybe a minor leak, can't really tell, kinda feels like there might be a puff of air when I open the throttle really fast.
I don't think it will make a difference tho, so I'm going to leave it as is and not mess with it no more. Sounds great and runs great too, don't look too bad neither, with the cheepo' cover I put on it.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28666 Tucson Az Gender:	Re: So I did the Dyna exhaust Reply #4 - 10/03/13 at 18:38:29 I like the cover OR,... don't worry about a tiny leak, it'll carbon up and seal in a few weeks... ...
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bobert_FSO Senior Member Offline SuzukiSavage.com Rocks! Posts: 421 Wichita KS Gender:	Re: So I did the Dyna exhaust Reply #5 - 10/03/13 at 19:23:28 Nice.
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babyhog Serious Thumper Offline Find a Cure for Breast Cancer! NOW!! Posts: 3802 WV Gender:	Re: So I did the Dyna exhaust Reply #6 - 10/04/13 at 05:15:48 Where'd ya get the cheepo cover? I like it! I want one.
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old_rider Serious Thumper Offline Backyard Bill Productions Posts: 3147 flordia panhandle Gender:	Re: So I did the Dyna exhaust Reply #7 - 10/04/13 at 05:31:15 babyhog wrote on 10/04/13 at 05:15:48: Where'd ya get the cheepo cover? I like it! I want one. Ebay http://www.ebay.com/itm/Chrome-Exhaust-Muffler-Pipe-Heat-Shield-Cover-Heel-Gu...
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walterpump YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 42 Southern Ontario Gender:	Re: So I did the Dyna exhaust Reply #8 - 10/15/13 at 17:25:16 Hey Old Rider: Where did you get the side bag supports I see in the pic? Just what I need. tnx & keep riding. PS: I should have your user name - I'm 72
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old_rider

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Re: So I did the Dyna exhaust
Reply #9 - 10/16/13 at 18:23:18

The side bag mounts were on the bike when we got it. I'll look around on the net see if I can find you a pair like them.

Call myself old_rider cause I been riding since I was 10 years old...I'm 54 now, but was told by the doc my bones are like a 70 year old woman, I got osteoporosis from a year one chemo therapy, I ain't complainin' tho, cause i'm still kicking.

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old_rider Serious Thumper Offline Backyard Bill Productions Posts: 3147 flordia panhandle Gender:	Re: So I did the Dyna exhaust Reply #10 - 10/16/13 at 18:39:37 I found this set, they should work http://www.ebay.com/itm/SUZUKI-SAVAGE-LS-650-CUSTOM-SADDLEBAG-SUPPORT-SUPPORT...
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walterpump

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Re: So I did the Dyna exhaust
Reply #11 - 10/17/13 at 07:24:11

Thanks for the link Old Rider, much appreciated.
You probably have heard the saying, "every day above ground is a good day."
Today I think temp is climbing to approx 70F here in southern Ontario, so I am going to take the afternoon off from rehabing the windows on my old house and go for a toot on my Savage. Have only had the bike for 3 or 4 weeks and have around 3000km on it (1800+ miles). Lovin this bike.
Have a great day.

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Super Thumper

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Re: So I did the Dyna exhaust
Reply #12 - 10/17/13 at 08:13:35

Because Suzuki has seen fit to put a "Kink" at the end of the exhaust pipe where it meets the muffler you need to loosen the two bolts at the cylinder head exhaust flange so the pipe is loose enough to rotate a little bit and allow you to slip your muffler on with no binding.

I used these exhaust reducers....

http://www.ebay.com/itm/Motorcycle-ATV-exhaust-pipe-muffler-reducer-sleeve-ad...

Slip the largest reducer over your exhaust pipe then the Dyna over that...tighten the clamp so the muffler and pipe are tight.

Then assemble the muffler mount bolt to the muffler support bracket but DON'T tighten it yet.... align the exhaust so everything fits then tighten your exhaust bolts at the cylinder head and the support bracket bolt...take baby steps here while looking for any binding and you will be ok.

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28666 Tucson Az Gender:	Re: So I did the Dyna exhaust Reply #13 - 10/17/13 at 08:29:34 I like that, ST... No cutting yer'self making a tin can sleeve,.. and no need for two clamps as with the extension adapter... Looks like a pretty sanitary solution... ...
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Super Thumper

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Re: So I did the Dyna exhaust
Reply #14 - 10/18/13 at 08:15:11

Thanks Sero..... I think Suzuki did this (the "kink" in the pipe) just to make it difficult for us folks to switch mufflers.

I am looking to make a single wall exhaust pipe with a larger 1.5: ID for better exhaust flow and without that silly little "Kink" at the end so we can clip mufflers on and off without all the hassle.

I have a pipe bender...need to order the dies for the 1 5/8" OD pipe....making the collar is the hard part...needs to be precision cut with a professional laser or plasma cutting table.

This is where I run into problems...pro fab shops want to make 100's of them at once. I'm still looking for a shop that will make me about 30 to start with.

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