SuzukiSavage.com - Trouble with Dyna Muffler

ClayJo

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2018 Suzuki S40

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Trouble with Dyna Muffler
10/12/25 at 20:09:23

Hey guys, I recently bought a 2018 S40 and have followed this thread to rebuild and rejet my carb, install a raptor petcock and raise my seat. So here I am at the last piece of the Trifecta, doing the Dyna slip on. I bought the 65747-94 model which requires the least amount of work. I followed Serowbot's guide to install using tin can gasket and T bolt clamp but I cannot get this thing to seat fully. It stops with about a quarter inch gap left. I've attached photos. Any help us greatly appreciated. This is my first post so I hope I am following the proper procedure. - Clay

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559518527_2869793760078353_4692481861838637871_n.jpg

Raptor Petcock, Spacer & Rejet, Dyna Muffler

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blod Senior Member Offline SuzukiSavage.com Rocks! Posts: 323	Re: Trouble with Dyna Muffler Reply #1 - 10/13/25 at 06:14:04 I used the exact same silencer on my Savage, I did not use a tin can gasket, it fitted perfectly without modification. I did not need to rejet the carb either Tip ! get one of these for a factory looking finish. https://www.ebay.ca/itm/174236617833?_skw=heat+shield+exhaust&epid=1704027501...
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ClayJo YaBB Newbies Offline 2018 Suzuki S40 Posts: 2 Toronto	Re: Trouble with Dyna Muffler Reply #2 - 10/13/25 at 07:07:41 Did yours sit flush with the end of the downpipe? Did you need to hammer it on? I tried the tin can gasket but am having a leak. I followed the guide and cut slits down the flange to help it on but it looks like it tapers inside and gets caught at the very end of the downpipe :'(
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blod Senior Member Offline SuzukiSavage.com Rocks! Posts: 323	Re: Trouble with Dyna Muffler Reply #3 - 10/13/25 at 08:16:58 I can't remember having to hammer it on, I think it was just a push fit. My silencer slits are not cut Try shortening your down pipe ( a little bit at a time ) so that it fits properly, it's less likely to leak then.
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uranusklingon YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 23	Re: Trouble with Dyna Muffler Reply #4 - 10/13/25 at 10:46:42 I started doing the tin can gasket, but didn't care for it. I ended up just using some exhaust sealant goop from a tube from auto zone. Then I put an exhaust clamp on it. EVIL ENERGY 1.75" Heavy Duty U Bolt Exhaust Clamp, 1 3/4 Inch Stainless Steel U Muffler Clamps, Saddle Style, 2PCS
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Needles

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Re: Trouble with Dyna Muffler
Reply #5 - 10/14/25 at 05:55:25

I just used the epoxy from a muffler repair kit to seal the joint. If you loosen the head nuts on the exhaust up front, and don't tighten the hanger bolt, you can "wiggle" a tighter fit. The header pipe can turn a tiny bit, letting the muffler and pipe come into a better (not perfect) alignment. Then you use the epoxy to seal it. I used a stainless 4" auto muffler clamp that I got off Amazon to cover and hold the joint.

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Suzi_002.jpg

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blod

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Re: Trouble with Dyna Muffler
Reply #6 - 10/14/25 at 06:17:38

Needles wrote on 10/14/25 at 05:55:25:

I just used the epoxy from a muffler repair kit to seal the joint. If you loosen the head nuts on the exhaust up front, and don't tighten the hanger bolt, you can "wiggle" a tighter fit. The header pipe can turn a tiny bit, letting the muffler and pipe come into a better (not perfect) alignment. Then you use the epoxy to seal it. I used a stainless 4" auto muffler clamp that I got off Amazon to cover and hold the joint.

What silencer are you using there ? The reason I ask is that it does not look like it lines up with the pipe.

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zipidachimp Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1473 surrey, b.c. Gender:	Re: Trouble with Dyna Muffler Reply #7 - Today at 01:21:32 Heavy Duty aluminum foil strip wrapped tightly with red exhaust paste, 1" wide clamp. Also agree with BLOD re: cutting excess exhaust so Dyna butts up against flange. J-B Weld High-temp red silicone exhaust paste. Worked for me! Cheers! ps: check the exhaust joint: https://postimg.cc/PNYQZtz5/e2014bf0
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