Tocsik wrote on 05/30/18 at 12:57:53:I've heard it can be pretty hard to get the stock muffler off the header pipe and that it's recommended to take the whole system off. The amount of force it may take to get the muffler loose from the header puts too much stress on the header bolts. Better safe than sorry.
^^ What he said.
Undo the the header bolts
Undo the muffler bracket bolts
Undo the heat shelf bolts
Lift the whole lot off
Then disassemble the exhaust system
It's much easier.
But when reinstalling, first attach the header pipe (loosley, so it can still rotate) then get the muffler in position and attach (loosley). I only used one bolt, and loktite, because it doesn't line up exactly with the muffler rail. Then attach the heat sheild (very loosley). Then you can rotate the header a little, and jiggle the muffler to get it lined up the best you can. I slipped the home-made Hadley in at this point and got in position as best I could. Then make sure the heat sheild still lines up well enough. My header is slightly rotated away from the bike after all is said and done.
Oh! Don't forget to slip the muffler clamp over the intake on the muffler before doing all of that - doun't ask me how I know!
Then you can tighten up the header bolts first (do not over do it - light finger and thumb pressure is enough - too light is better than too tight!). Then tighten up the muffler clamp, then tighten up the heat sheild bolts.
Before you start, read the tutorial on here about cutting slots in the end of the Dyna muffler - if you haven't already.
Oh! And one of the heat sheild bolts is a through bolt that needs held on both sides of the bike. DO NOT reach around the front of the bike, to hold both bolts, if the header is hot - don't ask how I know.
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