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Tocsik

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Denver, CO
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Baffled
07/27/20 at 06:47:59

Bike sounded a little louder than usual when starting this morning. Not ridiculous but...different maybe. Thought maybe it just seemed that way since I've been driving my truck for the past 6 days or so. Maybe my imagination. But then I jumped on the freeway this morning and it really seemed loud. Got quieter after a bit so I though I'd lost the hearing in my right ear! Jumped on the throttle a little to pass a car and it sounded different than ever. Alternated between sounding like a straight pipe and quieter than usual so thought maybe the baffle had blown loose and sometimes slipped into position to block the pulses. Anyway, motor too was hot when I got to work to check anything other than visual. Will check the nuts at the outlet before riding home and wiggle the header joint. In the meantime, tried to snap a pick down the barrel to get some thoughts from y'all. Looks a little odd to me up in the back of the muffler. Any thoughts?
Seems to be running OK.

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baffle_002.jpg

« Last Edit: 07/27/20 at 09:29:39 by Tocsik »

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4406 Honolulu	Re: Baffled Reply #1 - 07/27/20 at 11:34:19 What a cool picture. Really provides the details of the interior of the muffler. Looks to me like the wall of the baffle melted. There's a huge hole in the wall and what appears to be a ball of slag laying in the hole. That thing gets hot. Is it a Dyna muffler with catalyst?
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Tocsik Serious Thumper Offline the singularity Posts: 1163 Denver, CO Gender:	Re: Baffled Reply #2 - 07/27/20 at 12:37:24 It's a regular Dyna. Fortunately, I bought the pair so I can put the other one on. This one only has about 22K miles on it. Do Harley's blow 'em out like this, too? Can it be fixed without drilling the outer chrome? I had to raise my phone up a bit b/c of sun glare or I could have got up inside a bit more I think. Gonna be a LOUD ride home
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verslagen1

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Re: Baffled
Reply #3 - 07/27/20 at 12:50:48

I had the same problem at about the same mileage.

this was for the stock muff, but it could be applied for the dyna
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1526453881/0

If I remember correctly, the center baffle tube is a slip fit at the front, and welded at the back. It has a centered blocking plate that will redirect the flow into the muffler. The perforated tube can be purchased in many diameters.

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stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2641 Auburn, AL Gender:	Re: Baffled Reply #4 - 07/28/20 at 06:52:51 Harley Dyna with cat after a 2 hour interstate ride. And my bike is tuned slightly rich. Yep, it gets hot in there...
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Tocsik

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Re: Baffled
Reply #5 - 07/28/20 at 07:12:48

Cripes! Looks like a forging furnace in there.

As an update, the ride home was interesting. Bike initially started up loud; like a straight pipe sound. As I rode, something shifted into position and the exhaust went nearly silent. Very unsettling. I babied it a bit to be sure there wasn't too much back pressure somehow but acceleration etc. seemed fine. Downshifting and slowing for stops would dislodge things again and the first second of acceleration each time would be loud until whatever moved back into position and the bike had the same super-quiet stealth mode. Seriously, quieter than the stock muffler.
I removed the exhaust last night to check things out and found the plug at the end of the baffle is loose and rattling around.
A couple pics of it in different positions. Plus the cool, spiral screen at the other end.

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baffle_plug_collage.jpg

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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10670 Oklahoma Gender:	Re: Baffled Reply #6 - 07/28/20 at 07:17:51 stewmills wrote on 07/28/20 at 06:52:51: Harley Dyna with cat after a 2 hour interstate ride. And my bike is tuned slightly rich. Yep, it gets hot in there... Your muffler has a Fiery Red Interior ! Or is that a Warp Drive Unit ?
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stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2641 Auburn, AL Gender:	Re: Baffled Reply #7 - 07/28/20 at 11:27:05 LANCER wrote on 07/28/20 at 07:17:51: Your muffler has a Fiery Red Interior ! Or is that a Warp Drive Unit ? No, that's the "PRESS HERE for complaints" button
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DragBikeMike

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Re: Baffled
Reply #8 - 07/28/20 at 12:09:24

"Plus the cool, spiral screen at the other end."

That cool spiral screen is the catalyst. You have a catalyst muffler. Catalysts run extremely hot by design, and if the mixture is on the rich side, things get even hotter. A misfire condition will also cause a catalyst to overheat (unburned fuel runs through the hot catalyst and burns in the muffler).

It's very difficult to run a catalyst on a carbureted engine because a carburetor cannot maintain perfect air/fuel ratio over the entire operating range. Fuel injection solves that problem.

I would look for an un-catalyzed muffler. You will be able to run your mixture a tad on the rich side without turning your muffler into a crematorium.

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Tocsik Serious Thumper Offline the singularity Posts: 1163 Denver, CO Gender:	Re: Baffled Reply #9 - 07/28/20 at 15:04:37 Well that's odd. I thought only California required the catalyst (for motorcycles). Not sure why I thought that. I grew up there and moved away in '95. I bought these from a local in Denver. To get back on the road I'll use the other muffler from the pair but will keep this in mind. Thanks.
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stewmills

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Re: Baffled
Reply #10 - 07/28/20 at 15:17:42

DragBikeMike wrote on 07/28/20 at 12:09:24:

"Plus the cool, spiral screen at the other end."

I would look for an un-catalyzed muffler. You will be able to run your mixture a tad on the rich side without turning your muffler into a crematorium.

Agreed. I got this for $20 (a pair for $40) local in new condition and knew it was the CAT version despite really wanting one without (I am in AL...dunno why mine has a CAT but it does...maybe someone rode a CA bike down here?). I figured I would ride it until it started to show blueing on the outside, and that was ~5 years ago and it still looks new on the outside. When this one burns out I will source a non-CAT version on the next go-around.

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MMRanch

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Re: Baffled
Reply #11 - 07/30/20 at 16:41:53

Tocsik asked : Do Harley's blow 'em out like this, too?
....................................

Yes , I had a 2007 883 (fuel injected) Sportster. When it melted I was on the way from Lynchburg Tn. to Mena Ar. (South Central Arkansas) . The day was hot and I was running 75-80 mph for a long time.
Two weeks later I noticed there was no exaust coming out the rear of the back muffler . Thank goodness for the cross-over pipe!

I put on a pair of 12" shorties with DB-Killers in them and that was the end of the problem.
I've tried the same mufflers on the S-40 but have found they need a lot of muffler packing rolled in there on the motor end and then the DB-Killer at the rear. Don't trust those little bolts that come with the DB-Killers --- the person behind you when they blow out gets mad ! Roll Eyes

https://www.ebay.com/itm/EMGO-80-45700-MUFFLER-SLASH-CUT/133334066758?_trkpar...

This is the good stuff .
https://www.ebay.com/itm/CERAMIC-SILENCER-EXHAUST-MUFFLER-PACKING-KIT-1-THICK...

They come in a long version too.

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DB_Killer_002.jpg

« Last Edit: 07/31/20 at 08:09:25 by MMRanch »

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