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Message started by bacon13 on 06/19/06 at 13:06:44

Title: sportster muff install
Post by bacon13 on 06/19/06 at 13:06:44

I am about to get my new muff delivered and am figuring out how to do this install. I read the post in the tech section by bobo383. Great info and I get it.

I am wondering about the last post by pgolden where he refers to getting a 6 or 7 inch adapter. Can others recommend either using the adapter or not using it? What are the benefits of using the adapter? What have you all used to create a good seal between the muff and the head pipe other then pop can metal?

Title: Re: sportster muff install
Post by Dynobob on 06/19/06 at 13:13:50

Without the adapter piece, which should have a slight bend in it, your exhaust will dump out right on the rear brake backing plate and brake lever. The problem is mostly cosmetic, but for the price an exhaust place would charge you to make the adapter...why not go for it ?

Title: Re: sportster muff install
Post by Savage Librarian on 06/19/06 at 13:15:58

Well, I can't identify the adapter or provide any information in it...I think (note: think) that's an adapter to point the muffler a bit away from the rear brake rig, to keep it nice and clean.

I just took the stock can off, stuck the sportster muff on, clamped it with a muffler clamp I picked up at Autozone or one of those places, and there it is. A bit later I added a heat shield for looks, but that was basically all there was to it. Took a little effort to force the HD muffler on, but nothing too bad. No adapter for me.

Title: Re: sportster muff install
Post by smokey02 on 06/19/06 at 21:20:42

I mounted a HD turnout on my 96 using the original 2 bolt holes. Had to make an adapter to bridge the gap. 7 inches of 1 3/4 pipe, with about a 3 deg bend (10 deg was too much) and the header end flared to 1 11/16 and slit 2 places with a hacksaw about 3/4" deep. Also used "muffler mender" to seal it at the header end. Used HD chrome clamps at both ends of the adapter. Fairly tight joints, had to sort of wrangle it together, but No Leaks. I'll try to get a pic up soon. I think I'll need a heat shield that is 10 inches long to cover it all including where the chrome is a bit missed up at the end of the header.

Title: Re: sportster muff install
Post by Brewbrother on 06/20/06 at 16:30:05

What kind of sportster muffler did you get?? I installed a slash cut sportster muffler. It did require a little Persuasion. Don't forget the gasket. Mine was stuck inside the muffler. Took a little bit to get it out but, nothing major.

Title: Re: sportster muff install
Post by bacon13 on 06/20/06 at 17:56:10

I got a sportster 1200 off an 03.

Title: Re: sportster muff install
Post by wild one on 06/20/06 at 20:05:26

I installed a stock sportster muffler first without the adapter and then redid the install using the adapter. I like it better with the adapter. No stress on the header pipe and a better line. Needed the adapter to fit the muffler to the support bracket without stressing the header pipe. I have the muffler with the rail fastener, not the tabs. Picked up two of them from the local Harley dealer for $10. It's a big improvement over the stock muffler in look and sound. ;D

Title: Re: sportster muff install
Post by SeeAPierce on 06/21/06 at 20:55:50

Plenty of threads on this one - I am a fan of the adapter. 6 or 7 inches with a 10 degree bend and one end opened up enough to fit over the stock header. Two SS muffler clamps and you're all set up. I like the looks and sound...

Title: Re: sportster muff install
Post by SavageDude on 06/21/06 at 21:38:27

Ditto as SeeAPierce, I think 5-6 in. adapter with less than 10 degree will be perfectly align with the original muffler's mounting hole(via a home-made L bracket ). Bike sound like a real MC instead like the lawnmover ;D

Title: Re: sportster muff install
Post by pgolden on 06/21/06 at 21:42:51

I have a couple of pictures of the adapter posted on bikepics.com. Click on the link in my signature line to look at them.

Title: Re: sportster muff install
Post by bacon13 on 06/22/06 at 13:41:34

Thanks for the info. I saw your pics pgolden. I will print them out to show the muff shop guys.

Does the 10 degree bend or 3 degree bend work better? I see both have been used.

Title: Re: sportster muff install
Post by smokey02 on 06/23/06 at 07:40:53

I have the 3 deg bend on 7 inch pipe, will try to get pics tomorrow (sat)

Title: Re: sportster muff install
Post by smokey02 on 06/24/06 at 11:15:23

Here's some pics of my HD turnout (80000-84A) installed on my 96.
I bought a pair for $60USD on ebay. There's Harley Davidson script
on one of them, I used the plain one without any markings.
http://w1.bikepics.com/pics/2006%5C08%5C05%5Cbikepics-648973-800.jpg

Detail of the 7 x 1 3/4" adapter pipe and the HD clamps.
http://w1.bikepics.com/pics/2006%5C08%5C05%5Cbikepics-648962-800.jpg

Rear brake lever clearance.
http://w1.bikepics.com/pics/2006%5C08%5C05%5Cbikepics-648967-800.jpg

Front view.
http://w1.bikepics.com/pics/2006%5C08%5C05%5Cbikepics-648974-800.jpg

Samson H-129 10" Long Heat Shield. http://w1.bikepics.com/pics/2006%5C08%5C06%5Cbikepics-649434-800.jpg

It's a just a little loud, but not annoying. My friends mostly say it
"sounds like a real motorcycle now". It crackles a bit when I upshift,
has a muted "jake brake" sound when I slow down, only a little "poof"
when I turn it off. No more loud backfires.

Title: Re: sportster muff install
Post by bacon13 on 06/24/06 at 14:40:34

Nice look. Thanks for the pics. I got my sportster on without the adapter. It didn't look like I could use an adapter and use the mounting tab I bent on the sportster. I hardly got the muffler seated far enough on the header pipe so the tab would meet with the stock mounting bracket. Drilled a new hole and did get it mounted though. Not sure how to get it seated better on the header pipe?

My sportster header end narrowed inside the opening. This caused the header pipe to not slide far enough inside. I had to muscle it on the rest of the way. I think I ruined the gasket at the motor when I was banging the muffler on. There is now a little wiggle with the header pipe and an exhaust leak at the motor. I'm hoping a new gasket is all it takes to fix that.

Is there an easier way to get the muffler on without using a hammer to pound it on the header pipe? I did use a hack saw to cut two slits in the end of the header pipe to help coax it in the narrow muffler end. Not sure if that worked or my hammer did it.

Where can I find a good used or inexpensive new header pipe. Mine is missing most of the chrome on the bottom side and is pretty ugly next to the shiney new muffler. Dealer wants $140 bucks for new one. I never see them on ebay or this site.

http://i25.photobucket.com/albums/c57/bacon13/Picture_3255.jpg

Title: Re: sportster muff install
Post by bacon13 on 06/27/06 at 18:41:59

Can't seem to get a good seal at the motor. I bought a new gasket and put that in. I still have a leak there.

Any trick to get a good seal at motor?

Title: Re: sportster muff install
Post by pgolden on 06/28/06 at 08:44:39

The adapter keeps the header pipe out of a bind. I had the same problem before I had the adapter made. Take the header pipe and muffler with you to the muffler shop. Replace the engine/header pipe gasket.

Title: Re: sportster muff install
Post by Dynobob on 06/28/06 at 21:15:52

bacon13 wrote:

Any trick to get a good seal at motor?

Tighten the header bolts at the motor first. After you have this connection tight, worry about tightening the mounting bolts/bracket.

Title: Re: sportster muff install
Post by marlin72 on 08/09/06 at 17:36:07

bacon13 wrote:

Title: Re: sportster muff install
Post by barb36jack31 on 08/09/06 at 18:11:34

Bolted up a SuperTrapp and it went on just great. Super sound and performance. A bit pricey though, but worth it.

Title: Re: sportster muff install
Post by thumperclone on 08/10/06 at 21:10:51

bacon13 wrote:

Can't seem to get a good seal at the motor. I bought a new gasket and put that in. I still have a leak there.

Any trick to get a good seal at motor?

hi temp rtv tighten head pipe after all other connections are finger almost snug(you have to rotate the adaptor)
dont dril your stock pipe hanger bend a flat bar to work..sooner or later your goin to get tired of the harley junk and buy a hard krome...jmo