SuzukiSavage.com - Ryca Muffler Adapter

Kenny G

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Re: Ryca Muffler Adapter
Reply #30 - 04/01/15 at 20:33:03

Chris,

I am anxious to see what you come up with for an "extension for the extension".

The biggest problem with relocating a hole in the extension is coming up with an 18 millimeter (or 3/4") drill bit to bore the hole and reuse the rubber bushing, and the sleeve inside of it.

Since I test rode the bike for an hour I am thinking that adding to the frame extension may be unnecessary, but if you come up with something simple enough I will probably do it.

Lancer's jet kit arrived today, but I am going to wait until after Easter Sunday to another project.

Kenny G

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Todd James Full Member Offline SuzukiSavage.com Rocks! Posts: 238 Mansfield, Ohio Gender:	Re: Ryca Muffler Adapter Reply #31 - 04/01/15 at 21:48:00 KennyG: My local muffler shop made an adapter the same as your's. I posted a picture of the finished installation with information about the heat shield I used. Here's a link to the post - see Reply No. 3: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1375716388/4#4
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Ryca Muffler Adapter Reply #32 - 04/01/15 at 21:53:14 Todd, Thank you. I just ordered the heat shield like you show in the pic. That will make the job look finished. Did you have any trouble aligning thew carriage bolt with the muffler and the frame extension? Kenny G
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Todd James Full Member Offline SuzukiSavage.com Rocks! Posts: 238 Mansfield, Ohio Gender:	Re: Ryca Muffler Adapter Reply #33 - 04/01/15 at 22:16:44 I made an extension for the factory bracket using a metal strap from the hardware store, I filed out two of the holes square to fit the carriage bolts.
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Ryca Muffler Adapter Reply #34 - 04/01/15 at 22:52:56 Todd, Thank You. I knew there had to be a simple way to do this, I just couldn't think of anything, which is why I drilled the additional hole in the frame extension. I will keep a look out for that strapping the next trip to the hardware store. Kenny G
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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Ryca Muffler Adapter Reply #35 - 04/02/15 at 18:53:27 That looks like what I just did. I bolted a piece of 18 gauge (?) hurricane strap to the extension so I could use 2 bolts. BTW Todd, I think that piece is called a mending strap or something similar.
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Ryca Muffler Adapter Reply #36 - 04/02/15 at 19:47:25 Kris, Were you still able to use the rubber bushings and metal sleeves to mount the muffler? Kenny G
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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Ryca Muffler Adapter Reply #37 - 04/03/15 at 18:46:45 Yes, the mounting is rock solid now. No more chasing my muffler down the road now!
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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Ryca Muffler Adapter Reply #38 - 04/03/15 at 19:27:57 The best part is that the bolts/nuts holding the bracket to the muffler actually space the end away from the frame extension. I just used longer bolts to attach the bracket to the frame. This will move the end of the muffler away from the brake arm. Hopefully it's enough and the brake arm will stay clean!
Back to top	There's no problem that a full tank of gas and a sunny day can't fix! 2008 S40, Rotella T 15W-40 w/ZDDP added, Dyna, 140/90-15, Battery Tender Jr., Seat lift, #52.5/150/3 washers, Raptor IP Logged

Kenny G

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Robson Ranch, Denton, Texas
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Re: Ryca Muffler Adapter
Reply #39 - 04/03/15 at 20:23:53

Kris,

I am glad that your method of attachment worked out so well for you.

I have been out riding a couple of times, and re-tightened the exhaust fasteners and clamps. The Harley exhaust clamps are the key to my setup having worked. I am satisfied that the one bolt holding the muffler to the frame extension will be enough because the groove in the frame and the protrusion on the muffler mate together perfectly.

I am sure, other than adding a heat shield, this is as far as I am going to go with the Dyna.

I will say it again, "If I had it to over again I would buy the Ryca Adapter".

Kenny G

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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Ryca Muffler Adapter Reply #40 - 04/03/15 at 20:29:28 I'm sure 1 bolt will work just fine. I'm just gun shy having lost the muffler due to vibration (I guess). Maybe a lock nut or thread locker would be a good idea.
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Kenny G

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Singles Club...LOL

Posts: 1754
Robson Ranch, Denton, Texas
Gender: male

Re: Ryca Muffler Adapter
Reply #41 - 04/03/15 at 21:06:45

Kris,

Here is what I did that might help you.

I used a "Jam Nut" to hold the carriage bolt to the muffler while aligning everything. When I was finished, and after test driving, I put a "Lock Nut" on top of the "Jam Nut".

Using the Harley clamps, which are really heavy duty, locked the three pieces of the exhaust system together as solid as a rock.

Kenny G

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Todd James

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Re: Ryca Muffler Adapter
Reply #42 - 04/03/15 at 22:30:40

Kris:
Your right. It's a Mending Strap.
I forgot the name of it. Thanks.

KennyG:
I agree with Kris that one bolt should hold it since
the muffler rail is nested into the frame extension.
The Harley clamps are definitely the best ones to use.
Be sure to check everything for tightness several times
during the next few hundred miles. I found that the
bolts holding the header to the engine had loosened up
after a few heat cycles and some bumpy roads.
Post a pic for us after you get the heat shield installed.
Sounds like you thought this out well. Good work !

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2007 S40, Dyna, 52.5/150, .073 Spacer, 2 Turns
2007 Sportster 1200, V&H Pipes

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Kenny G

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Re: Ryca Muffler Adapter
Reply #43 - 04/03/15 at 22:53:51

Todd,

I am a fanatic about re-checking fasteners on a motorcycle after working on it. Over the years I found out everything the hard way about the vibration on single cylinder bikes.

I will make sure that I continue to keep checking the bolts that hold the header onto the engine. I wish Suzuki had used studs and lock nuts rather than the bolt arrangement.

I will post a pic as soon as the heat shield arrives.

Kenny G

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Kris01

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Re: Ryca Muffler Adapter
Reply #44 - 04/04/15 at 12:20:58

Speaking of....

I've heard lots of horror stories of having to drill out the header bolts once they were over tightened and snapped off. Anyone know what size and thread pitch the header bolts are? I guess I could take one to the hardware store and check it. Maybe one of you guys know.

I was thinking of replacing both of them with studs. After doing everything else to this exhaust system (more than once), it might be safer to go ahead and put studs in place of the bolts.

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There's no problem that a full tank of gas and a sunny day can't fix!

2008 S40, Rotella T 15W-40 w/ZDDP added, Dyna, 140/90-15, Battery Tender Jr., Seat lift, #52.5/150/3 washers, Raptor

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