Hi, I'm seeking for help in upgrading my stock muffler on the 2007 Boulevard S40 Bike.  I've done some research on this upgrade a while now and would like to really start getting the exhaust swapped.  My hope is to make the bike sound a bit better and louder then existing one on it.  I've learned that you can install the stock Dyna muffler just fine without welding or cutting involved?. I would like to confirm on it.  Secondly I've found a used stock 09 HD Dyna glide muffler on ebay selling for cheap. Can I use this muffler in place of my stock's?..



A buddy of my also lent me two of his Stock Mufflers from his 2012 Sportster Fortyeight.  I know it has dual muffler but can I still use one of them and modify it somehow to make it work, and perhap it might make the bike sound better? Since it is free.  Please advise. Thanks in advance.

yup, that'll work

I have the same one on my "quiet bike"

Been thinking of this. How's the sound of the HD muffler?

Thank you so much for all the replies.  Also, dont you have to rejet? And what are the size of needles i need to replace?

LiPix wrote on 11/04/14 at 05:30:25:


The folks that do not use the adapter.....cut several slots in the front of the muffler where it slips on the header pipe, and they use a tin can shim.  These slots allow the muffler to be deformed to "re-angle" the front of the muffler.  I prefer the adapter to correct the angle - but it does cost more money.

In my case simple heating and cooling over time has softened the steel of the Dyna joint to the point it has conformed to the angle and the diameter that is needed.   The Dyna existing slots have a little ear or tab at the mouth end of the slots that needs to be removed with a metal cutting shear to allow the mouth to reduce its diameter enough and to realign some as it closes down to make the correct angle.

The tabs at the mouth of the existing slots prevents both the shifting and the diameter close down ..... so either cut them or 4  1/2 grinder the mouth tabs away.

You put the muffler in place with some muffler cement in the joint, force the header on deep into the joint then force the parts into location on the bike, then you tighten the clamps down.  The first time their is misalignment and the joint will leak eventually, then you take it apart, clean off the cement and redo it (and the muffler mouth keeps lining up better and better as you go along).

Dyna mufflers eventually get noisy as the center pipes erode and the seal off between the central chambers goes away.   Then you go get another used Dyna as they are still the best priced best performance aftermarket muffler for the Savage.

Somebody will eventually make up a bunch of adapters and have them for sale, then we won't have to do these "make does" any more.

I'll go ahead and add in my $.02 as well. I found a dyna muffler off ebay for around 30. Had to buy the Ryca adapter, I believe 50?, but it was worth it. Gave me adjust-ability in the angle I want.

As far as sound, I have never heard the stock muffler in person, but it is definitely tamer than the couple EMGOs I previously used. Still has enough mmpph to it tho. I can't hear it when I'm cruising, just when I really get on it or am at a stop.

I'm curious as to others rejets as well. I've been running, if I can remember correctly, stock pilot, 150 main(or maybe 152.5), one washer on needle, and about 3/4 turn out on screw. This runs pretty good and just has a little hmmpphhtt at shut off at times.

savskad wrote on 11/04/14 at 13:07:55:


It's just a short heat shield that you can find on fleabay, 6 to 9" long.