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SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Issue Installing new HD Dyna Muffler /cgi-bin/YaBB.pl?num=1462838310 Message started by savagerider on 05/09/16 at 16:58:30 |
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Title: Issue Installing new HD Dyna Muffler Post by savagerider on 05/09/16 at 16:58:30 Hey everyone, I need some help. I just bought a Harley Davidson Dyna Muffler (685747-94) and I am trying to install it. I am following this guide: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1298689417 I am following it step by step. I am now trying to attach the new muffler onto the exhaust pipe but I am running into an issue - it is not going on all the way. I cut 6 slots into the pipe and even pryed them apart a little to make it wider so it will fit. Still didn't help. Here are some images: http://i.imgur.com/5qrkPqUl.jpg http://i.imgur.com/QYgJZRZl.jpg Any suggestions? |
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Title: Re: Issue Installing new HD Dyna Muffler Post by engineer on 05/09/16 at 17:39:00 Something doesn't look right, not sure what is going on there. Maybe you are trying to get it too far in, it doesn't have to fit all the way. The Harley Dyna has a bigger diameter opening than the Savage pipe. Anyway I made an adapter for mine which makes the angle of the Dyna line up a little better. Dave has a thread on this method in the tech section with drawings and pictures. His is a very nice piece of work. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1353284557 I made mine a little shorter and managed to use both mounting points. Mine was made from an exhaust pipe adapter I bought at a NAPA store. I took a slice out of it and re-welded it to get the angle and expanded one end a little and cut it to length. Mine looks a little crude but I covered it with a cheap Ebay heat shield. Others have found a simpler way which is to go to a muffler shop and have them make the adapter. They have equipment to make the bend and to expand the pipe. You could copy Dave's drawing and show that to them. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by DesertRat on 05/09/16 at 19:24:46 you're MISSING the adapter that slips between the stock exhaust pipe and the Dyna muffler ... I did the Dyna MOD by Dave, with my own DIY twist: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1443386041/2#2 |
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Title: Re: Issue Installing new HD Dyna Muffler Post by bobert_FSO on 05/09/16 at 19:29:18 Nothing wrong there. The Dyna inlet necks down where the inlet to muffler casing is. It becomes smaller than the Savage header pipe. Just slide it on as far as it will go, then clamp the muffler down. The muffler does not have to reach the "ring" in the header pipe to seal or to clamp onto the header. If you really want the Dyna to slide up to the ring, you'll need to chop a little bit off the end of the header pipe. However in the long run, it doesn't make any difference. Some people use an angled adapter pipe, some don't. I didn't, and was able to still mount the muffler to the muffler bracket, but with just one bold at that point. It helps to loosen the header pipe at the head end so you have some wiggle room to get everything to fit. Tighten the head flange bolts last. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by justin_o_guy2 on 05/09/16 at 20:45:33 I don't see how that is gonna work out. The slots are past where you can get the end of the header, IMO. Don't go banging on it. The little bolts holding the header won't take it. If you're gonna get horsey with it, mark the muffler and header, take them off, rassle them off the bike. Do NOT, under any circumstances, use a grinder on the header and allow sparks near the battery vent tube. Trust me on this.. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by savagerider on 05/10/16 at 15:35:15 Alright well. I read what you guys had to say and I put on the muffler. I made sure to get a good clamp, and make sure the tin can was there to help crush it in a bit. I have a small exhaust leak (i felt the air coming out where the muffler and the exhaust pipe met) and some black smoke coming out ( i only ran it for like 30 seconds and gave it a little bit of throttle) Anything I should be concerned about? |
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Title: Re: Issue Installing new HD Dyna Muffler Post by striknein on 05/10/16 at 17:12:48 I had a similar issue with leaks. I solved it by wrapping the connection a couple times with muffler tape and clamping over it. Easy peasy. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by savagerider on 05/10/16 at 18:04:49 I am definitely going to buy another clamp. I am just using the stock one. It doesn't clamp down far enough. Think I should have any concerns with the black smoke? I read that it shouldn't be an issue if the engine is running cool (which it was) and that if it keeps up after its warm then its an issue. Just looking for a second opinion. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by striknein on 05/10/16 at 18:51:05 Black smoke indicates that the bike is running rich. That's perfectly normal for a bike that hasn't warmed up, and it's a problem if the bike is warm. What does the exhaust look like when it's been running for 20 minutes? |
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Title: Re: Issue Installing new HD Dyna Muffler Post by Kris01 on 05/10/16 at 19:11:24 I spread a layer of high-temp caulk around the header, wrapped it in several layers of aluminum foil, more high-temp silicone and then a layer a thin sheet metal cut to fit. I used enough layers of aluminum foil so that attaching the muffler was a tight fit. I already had a clamp on hand that I wanted to use. No use in buying something if you already have it. It's stainless steel and used to connect PVC pipes with a rubber coupler. I just robbed the clamp for my exhaust system. It's a bit redneck but it works great! I never could get the tin can method to seal. I always had a leak. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by justin_o_guy2 on 05/10/16 at 19:42:53 I don't see how you can possibly get the header seated as deeply as some of the cuts. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by Kris01 on 05/10/16 at 21:14:29 I cut mine slightly too deep as well. That's where the aluminum foil and silicone came in handy. I tested for leaks by holding a candle around the joint and watching to make sure the flame didn't move. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by KennyG on 05/10/16 at 21:33:46 In my humble opinion: I really think that the adapter that Dave designed or the adapter that Super Thumper sells is the only reliable way to have a neat leak free installation that will last. I think genuine Harley Davidson clamps are the key to making the adapter work. Kenny G |
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Title: Re: Issue Installing new HD Dyna Muffler Post by savagerider on 05/11/16 at 03:29:24 KemnyG, Is it possible to order one of these cheap online? I don't have the tools to strip or cut anything off. Ideally I would like to get the adapter piece that I can just slip on and clamp and then be finished or whatever. I agree with you that this method looks the cleanest and simplest. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by Dave on 05/11/16 at 03:58:46 Although you may be able to find something cheaper if you run around to muffler shops and see what they will bend for you - the RYCA adapter makes the job easier, and it is chrome and looks nice. http://shop.rycamotors.com/exhaust_adapter.html |
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Title: Re: Issue Installing new HD Dyna Muffler Post by justin_o_guy2 on 05/11/16 at 05:30:10 It's pretty, alright, but for Fity Dollars I would expect a T clamp. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by KennyG on 05/11/16 at 05:38:07 Justin, The Ryca adapter is a little salty. I gave the guy $20.00 to make my adapter, but he actually took the header and muffler and formed the adapter to fit. All I had to do was trim the right end to fit squarely on the header after test fitting to my S40. Mine is made out of aluminumized steel tubing rather than being chrome plated. I installed a chrome heat shield from Amazon over the adapter to hide it. Kenny G |
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Title: Re: Issue Installing new HD Dyna Muffler Post by Dave on 05/11/16 at 05:39:57 445B5D5A4740714171495B571C2E0 wrote:
It is one of those supply and demand, economy of scale type of things. How many of these does RYCA have made at a time.....50 - 100? RYCA fond a small company that will build them in small batches and they have to order the tubing, cut it, bend it, expand it - then ship it off to the plater, then deliver it to RYCA - then RYCA has to order and add a clamp for it, stock it, store it, market it on their website....pay taxes on the building and keep their employees paid and insured. It isn't easy to run a small business that caters to guys using Savage bikes for Cafe' and Bobber projects. The small local muffler shops that do this for you....most likely they are doing you a favor, and chances are they aren't making any money when they build you an angle adapter. Thankfully - there still are folks around who will help us out - and hopefully you take your car back to them when you need a muffler! |
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Title: Re: Issue Installing new HD Dyna Muffler Post by justin_o_guy2 on 05/11/16 at 05:41:34 That's a tidy installation, might consider putting the sellers contact information in a sticky, so others can get one. Surely there is a sticky on exhaust system stuff. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by Dave on 05/11/16 at 06:40:06 2F3036312C2B1A2A1A22303C77450 wrote:
Yep....if you want to go into the business, you could have the fellow make you up a bunch, and then list them in the Marketplace. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by KennyG on 05/11/16 at 06:47:43 Dave, That would be a good project for someone that doesn't have enough to do. Believe it or not at 78 years old it doesn't take much to keep me busy. Super Thumper already has a working setup, perhaps he could make just the adapter and heat shield available to the guys on the forum. Kenny |
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Title: Re: Issue Installing new HD Dyna Muffler Post by Tocsik on 05/11/16 at 07:09:46 I would be up to purchase one! |
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Title: Re: Issue Installing new HD Dyna Muffler Post by Art Webb on 05/11/16 at 07:15:25 doesn't super thumper sell the full full kit including muff for like $40? that's a bargain, and you have the adapter for the next muff install, too |
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Title: Re: Issue Installing new HD Dyna Muffler Post by KennyG on 05/11/16 at 08:47:31 Art, You are correct, Super Thumper's setup is the least expensive way to get a decent muffler on to a Savage/S40. Kenny G |
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Title: Re: Issue Installing new HD Dyna Muffler Post by justin_o_guy2 on 05/11/16 at 21:18:58 1C272A3D2C203B3D262E233C4F0 wrote:
Yep....if you want to go into the business, you could have the fellow make you up a bunch, and then list them in the Marketplace. [/quote] I already have a very time consuming venture. Somebody has to read posts and distribute stars. |
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Title: Re: Issue Installing new HD Dyna Muffler Post by KennyG on 05/11/16 at 21:27:49 Justin attaboy LOL Kenny G |
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