SuzukiSavage.com - Going back to stock muffler

karl

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Going back to stock muffler - need advice
07/05/16 at 19:06:29

Hi all - new to the forum, I'm here on behalf of my lovely wife who just scored a pretty yellow 1996 Savage with about 3000 miles on it! Previous owner fitted it with a ridiculously loud (in our opinion) aftermarket muffler, and we'd like to swap it out for a stock one. So, a couple of questions:
1) Are all model year mufflers for this model interchangeable, or is there only a certain range of years that will fit?
2) Does anyone have one in good shape they'd like to get rid of or trade for the one we have? I'll double check later for sure, but I think it's a Jardine.
Thanks in advance for all your help. Much appreciated! - Kvdv

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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Going back to stock muffler - need advice Reply #1 - 07/05/16 at 19:09:20 The Jardine IS loud! Every model is the same from 1986 on. You have a huge list of years to choose from!
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stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2641 Auburn, AL Gender:	Re: Going back to stock muffler - need advice Reply #2 - 07/05/16 at 19:11:57 Don't go stock, go with a Harley dyna. Just a bit louder than stock, but not stupid. You'll probably get more response of the same, but if stock is what you want there are probably lots to choose from since lots of folks swap to the dyna.
Back to top	2008 \| 152/52.5–Air Mix 3/4 \| Rotella T4 \| Seat Lift w/Sheepskin \| Speedo Rattle \| Rear Pulley Shim \| 140/90-15 Rear \| Kaw Front Pulley \| Relocated Rear Signals FREEDOM ISN'T FREE! IP Logged

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Going back to stock muffler - need advice Reply #3 - 07/05/16 at 20:18:51 Easy, cheapest, excellent sound, Dyna muffler. The stock unit is fat, ugly, heavy expensive,and power robbing. Yes,the exhaust you have is way loud. And difficult to jet the carb to. If I f o und a Savage, id put a Dyna on it.
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karl YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 2	Re: Going back to stock muffler - need advice Reply #4 - 07/05/16 at 20:20:05 Fair enough...I'd consider the Harley exhaust...is there a part number that I should look for? Also, is it a direct bolt on or is there additional hardware required to fit it? Thanks again...looking forward to playing around with this thing. I may just have to get one for myself...what a cool bike!!
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striknein

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Re: Going back to stock muffler - need advice
Reply #5 - 07/05/16 at 20:40:53

karl wrote on 07/05/16 at 20:20:05:

Fair enough...I'd consider the Harley exhaust...is there a part number that I should look for? Also, is it a direct bolt on or is there additional hardware required to fit it?
Thanks again...looking forward to playing around with this thing. I may just have to get one for myself...what a cool bike!!

Most independent Harley shops will have a back room flooded with take-off exhaust systems. You're looking for one off a dyna; it's mounted to the frame using a slotted rail welded to the back of the muffler. You can also use one off a Soft tail, which has 2 threaded bungs welded to the back. Only one bolt will line up with the muffler bracket on the frame. Try to pick up a Harley muffler clamp when you get the muffler.

You'll also need an exhaust shim. EMGO makes a set that allow you to match the inner diameter of the muffler to the outer diameter of the header. You can find the set for 5 bucks on eBay.

An adapter pipe is an alternative to the shim. RYCA sells an adapter which extends the length of the exhaust system and angles the muffler away from the rear brake arm. They're effective, but they're also 50 bucks a pop.

You can also install a heat shield to cover up the clamps and make for a more professional looking install. I think I bought a 6" shield from eBay. It was cheap.

You can find a guide in the tech section of the site. Ignore the part about the crushed tin can and making relief cuts at the end of the muffler. If you take my advice instead, you'll have a leak-free system.

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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Going back to stock muffler - need advice Reply #6 - 07/05/16 at 20:54:33 Harley muffler guide... http://suzukisavage.com/cgi-bin/YaBB.pl?num=1298689417 Sportster muff installation http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1114360126 DYNA Muffler adapter http://suzukisavage.com/cgi-bin/YaBB.pl?num=1353284557
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

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Going back to stock muffler - need advice Reply #7 - 07/05/16 at 21:25:02 Avoid the catalytic converter year models. Some have crossover tubes.. not what you want.
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Wake51 Full Member Offline Murphy's Law Posts: 214 St. Louis Gender:	Re: Going back to stock muffler - need advice Reply #8 - 07/06/16 at 10:43:44 striknein, Would you happen to have a part number or measurement of the EMGO shim you used? I've had an exhaust leak utilizing my Dyna muffler that I just can't seem to solve with the crush can and slots method. I did a quick e-bay search but was only able to find Emgo mufflers.
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Kenny G Serious Thumper Offline SuzukiSavage.com The Singles Club...LOL Posts: 1754 Robson Ranch, Denton, Texas Gender:	Re: Going back to stock muffler - need advice Reply #9 - 07/06/16 at 10:51:07 Try Amazon https://www.amazon.com/Emgo-Muffler-Reducer-80-47310/dp/B00230CC0G/ref=sr_1_1... Kenny G
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verslagen1

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Re: Going back to stock muffler - need advice
Reply #10 - 07/06/16 at 11:50:08

Wake51 wrote on 07/06/16 at 10:43:44:

striknein,

Would you happen to have a part number or measurement of the EMGO shim you used? I've had an exhaust leak utilizing my Dyna muffler that I just can't seem to solve with the crush can and slots method. I did a quick e-bay search but was only able to find Emgo mufflers.

search "muffler shim" and this is what you want...

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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Going back to stock muffler - need advice Reply #11 - 07/06/16 at 16:53:14 I couldn't get the tin can method to work either. I ended up using a couple of layers of aluminum foil and some high temp silicone. Works great and won't blow out!
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

Wake51 Full Member Offline Murphy's Law Posts: 214 St. Louis Gender:	Re: Going back to stock muffler - need advice Reply #12 - 07/07/16 at 16:21:51 I actually found some at the local auto parts. Am I looking to shin from 1 3/4 to 1 5/8, or to 1 3/8? Can't remember the diameter off the top of my head.
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striknein Junior Member Offline SuzukiSavage.com Rocks! Posts: 51	Re: Going back to stock muffler - need advice Reply #13 - 07/07/16 at 19:11:34 Wake51 wrote on 07/07/16 at 16:21:51: I actually found some at the local auto parts. Am I looking to shin from 1 3/4 to 1 5/8, or to 1 3/8? Can't remember the diameter off the top of my head. It's 1 5/8"
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Wake51 Full Member Offline Murphy's Law Posts: 214 St. Louis Gender:	Re: Going back to stock muffler - need advice Reply #14 - 07/08/16 at 05:53:53 Awesome, that was the one I picked up. I'll pull open the exhaust tonight and see if I can't fix it, much to the dismay of my riding buddies. they scoff at the idea of me fixing the backfire, it's one of their favorite features.
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