SuzukiSavage.com - sportster muff install

bacon13

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sportster muff install
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?

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Dynobob Serious Thumper Offline 2003 LS650 (with Supertrapp) Posts: 634 Northern Virginia Gender:	Re: sportster muff install Reply #1 - 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 ?
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Savage Librarian

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Houston area
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Re: sportster muff install
Reply #2 - 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.

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Life is not a journey to the grave with the intention of arriving safely, in one pretty and well preserved piece, but to skid in broadside, used-up, worn out, and defiantly shouting 'Geronimo!!!'

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smokey02

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Re: sportster muff install
Reply #3 - 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.

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Maroon 96, HD turnout, Iridium, TKat brace, Big Crank, seat lift, Narva +50 w/ yellow filter in a XV920 9

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Brewbrother Serious Thumper Offline Just lending a helping hand. Posts: 953 Gender:	Re: sportster muff install Reply #4 - 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.
Back to top	Opportunities multiply as they are seized. No spacer,60 pilot jet, 155 main jet, plug door, sportster muffler, k&n drop in, iridium plug, brake pedal mod,de-badged, Dunlops, bullet turn signals. IP Logged

bacon13 YaBB Newbies Offline Posts: 46 Minnesota Gender:	Re: sportster muff install Reply #5 - 06/20/06 at 17:56:10 I got a sportster 1200 off an 03.
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wild one

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Re: sportster muff install
Reply #6 - 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. Grin

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SeeAPierce Senior Member 2005 No Login Offline Posts: 282 California Gender:	Re: sportster muff install Reply #7 - 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...
Back to top	'06 S40 green: sporty muff & 10 degree adapter 155 main jet, 1/2 white spacer, open filter, bar end turn signals IP Logged

SavageDude Serious Thumper Alliance Member Offline Posts: 561 OC_California Gender:	Re: sportster muff install Reply #8 - 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
Back to top	2005 S40, debadged, Tkat FB, saddle bags, sissy bar, HD Sporter muff, Fly screen, white spacer mod, 150 main jet.....and sssslowly upgrading IP Logged

pgolden Ex Member	Re: sportster muff install Reply #9 - 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.
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bacon13 YaBB Newbies Offline Posts: 46 Minnesota Gender:	Re: sportster muff install Reply #10 - 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.
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smokey02 Full Member Offline Time flies like an arrow, fruit flies like bananas Posts: 233 Alta Loma, California Gender:	Re: sportster muff install Reply #11 - 06/23/06 at 07:40:53 I have the 3 deg bend on 7 inch pipe, will try to get pics tomorrow (sat)
Back to top	Maroon 96, HD turnout, Iridium, TKat brace, Big Crank, seat lift, Narva +50 w/ yellow filter in a XV920 9 IP Logged

smokey02

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arrow, fruit flies
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Alta Loma, California
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Re: sportster muff install
Reply #12 - 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.

Detail of the 7 x 1 3/4" adapter pipe and the HD clamps.

Rear brake lever clearance.

Front view.

Samson H-129 10" Long Heat Shield.

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.

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Maroon 96, HD turnout, Iridium, TKat brace, Big Crank, seat lift, Narva +50 w/ yellow filter in a XV920 9

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bacon13

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Minnesota
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Re: sportster muff install
Reply #13 - 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.

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bacon13 YaBB Newbies Offline Posts: 46 Minnesota Gender:	Re: sportster muff install Reply #14 - 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?
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