SuzukiSavage.com - Harley muffler conversion, connection to header

Prophet_10

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Harley muffler conversion, connection to header
03/19/08 at 09:51:58

I just bought a Harley muffler from flightsim on ebay. I guess it is a Dyna:

http://cgi.ebay.com/ebaymotors/SUZUKI-SAVAGE-LS650-S40-E-ZY-HARLEY-MUFFLER-CO...

He includes instructions and mentions that you may need to remove the copper gasket on the header pipe to make the muffler fit.

I can't determine what he means by the copper gasket so I took a few photos to see if you guys can help me identify it. Or, if anyone has done this with the same muffler maybe you can offer some tips?

The problem I am having is that he says you need to slide the muffler on all the way to the ridge on the header pipe and mine stops short by slightly less than 1/4 inch. I am trying to figure out if I am going to need to hacksaw part off the header pipe off or something.

Any ideas? Here are the photos:

can you identify a copper gasket?

Here is how far it will go on before the inside of the muffler tapers down:

Another showing the limit. Also, the instructions say to use a couple of strips of aluminum cans around the header pipe (I get my beer from a bottle so I had to use soda cans); this shows what I was going to use, is it sufficient?

BTW, when I removed the header pipe the left bolt (right side of this pic) was kinda loose and I noticed some carbon at the bottom of the gasket and the pipe, I also saw some on part of the other end by the muffler. Does this indicate leaks or is it normal? Here is a photo of the gasket - it actually looks more black than the photo.

Does this gasket have to be replaced every time you remove the pipe?

Thanks for any help

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Yonuh Adisi FSO

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Re: Harley muffler conversion, connection to heade
Reply #1 - 03/19/08 at 10:57:01

Prophet_10 wrote on 03/19/08 at 09:51:58:

BTW, when I removed the header pipe the left bolt (right side of this pic) was kinda loose and I noticed some carbon at the bottom of the gasket and the pipe, I also saw some on part of the other end by the muffler. Does this indicate leaks or is it normal? Here is a photo of the gasket - it actually looks more black than the photo.

http://a874.ac-images.myspacecdn.com/images01/7/m_f6b3c10528ec97844ccd819c361...

Does this gasket have to be replaced every time you remove the pipe?

Thanks for any help

A loose header bolt will definitely give you an exhaust leak and could discolor the gasket like that. And no, you don't have to change the crush gasket every time unless it is unsalvageable.

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Gort

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Re: Harley muffler conversion, connection to heade
Reply #2 - 03/19/08 at 17:25:39

I ran into the same problem when I installed a Harley muffler on my '96 Savage. My Savage header pipe is 5/16" longer than the length of the inlet hole in the HD muffler. I couldn't get the HD muffler to slide up to the outside shoulder on the header pipe, so I measured everything and found the problem. I didn't want to cut the header pipe so I just pushed the muffler onto the header until the header stopped against the internal shoulder in the muffler, and clamped it tight. I've had no problems since then.

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thumperclone

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Re: Harley muffler conversion, connection to heade
Reply #3 - 03/19/08 at 17:38:45

een thru a couple of hd muffs on my 06 DO NOT hacksaw any thing that guy from land o' lakes is a(sluggo will fill in)..your problem is you are tryin to use a soda can gotta be a beer can..just kiddin me and dr jim are socializin 2nite..
get sum of that orange high temp gasket stuff by permatex..lube the os end of your header slide the hd muff on align your rear mounting (dont know which muff u got)tab...use a hd clamp at your head pipe muff connection.............im tired of typing.. do a tech section search
all you need to know is there..oh yea did you get a 7 deg adapter to keep the gasses off your brake ??

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Rockin_John

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Re: Harley muffler conversion, connection to heade
Reply #4 - 03/19/08 at 17:41:57

It appears your "copper gasket" is already missing. It is just a piece of shim stock about like the pieces of pop can you've cut for gaskets.

Can you not look down inside the muffler and see what it is that prevents it from slipping the rest of the way onto the pipe? Or is it just stopping because of the tight fit? (That's what mine did)

Anyways, I got tired of messing with the one on my 87 and just took it to a friends welding shop. With a die grinder/cutting wheel; I cut the slits on the muffler longer so it could slide on up the header pipe; then I used a regular car U-bolt muffler clamp to squish the pipe tight. When knocking the muffler onto the header, the was clamped in a big vise with wood to protect the chrome finish. Then I had him TIG weld the whole thing into a one piece system.

WARNING: If you weld as I did: make certain that you have everything positioned exactly how you want it to fit before you weld it!!!

If you use a new gasket at the cylinder, and your welder is good, there is NO WAY you'll have to go through all the leak detection and fixing problems of using clamps to seal the pipes. Your clamps will be for mounting only. Downside: If you want to change mufflers, it requires skillful cutting with a cut-off tool (die grinder) to get the welded muffler off.

I'm considering putting my louder and longer turnout muffler on my 99; which was bolted together by earlier owner/mechanic. Don't know if I'll resort to welding again or not. But if I have any leaking problems I won't hesitate to weld whichever pipe I finally decide to live with on that bike.

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Prophet_10

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Re: Harley muffler conversion, connection to heade
Reply #5 - 03/20/08 at 07:10:56

Rockin_John wrote on 03/19/08 at 17:41:57:

Can you not look down inside the muffler and see what it is that prevents it from slipping the rest of the way onto the pipe? Or is it just stopping because of the tight fit? (That's what mine did)

Hey John,

Actually, it doesn't fit because the inside of the muffler tapers down too soon for the entire pipe to fit in it.

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Prophet_10

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Re: Harley muffler conversion, connection to heade
Reply #6 - 03/20/08 at 07:11:06

thumperclone wrote on 03/19/08 at 17:38:45:

get sum of that orange high temp gasket stuff by permatex..lube the os end of your header slide the hd muff on align your rear mounting (dont know which muff u got)tab...use a hd clamp at your head pipe muff connection.....oh yea did you get a 7 deg adapter to keep the gasses off your brake ??

Thanks for the info, can anyone tell me what this "HD clamp" looks like or where to get one?

More importantly can you tell me where to get and what size 7 degree adapter you are talking about??

Sounds like I won't be riding anytime soon...

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Rockin_John

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Re: Harley muffler conversion, connection to heade
Reply #7 - 03/20/08 at 12:00:40

Prophet_10 wrote on 03/20/08 at 07:10:56:

Rockin_John wrote on 03/19/08 at 17:41:57:

Can you not look down inside the muffler and see what it is that prevents it from slipping the rest of the way onto the pipe? Or is it just stopping because of the tight fit? (That's what mine did)

Hey John,

Actually, it doesn't fit because the inside of the muffler tapers down too soon for the entire pipe to fit in it.

Well, there's a couple of ways you can go here: cut the muffler "slits" a little farther up so you can jam it up the rest of the way, or don't bother with that and just weld it where it is. (As long as your mounting brackets line up.)

If you prefer not to weld, then you do need to use either the H-D clamps from their parts dept. or an on-line supplier (eBay?) Or regular automotive clamps from the local auto parts store. (You end up hiding all this nasty stuff with chrome heat shield covers anyways if you want it to look pretty.)

The double or single bent adaptor pipe that keeps the exhaust from blackening your rear brake control lever and rod is optional. I don't have it on either of my bikes, and it's not that big of a deal. I had one made, but I didn't like the way it fit; and didn't want to do it all over again.

Good luck

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Gort

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Re: Harley muffler conversion, connection to heade
Reply #8 - 03/20/08 at 13:15:21

Prophet_10 wrote on 03/20/08 at 07:11:06:

thumperclone wrote on 03/19/08 at 17:38:45:

get sum of that orange high temp gasket stuff by permatex..lube the os end of your header slide the hd muff on align your rear mounting (dont know which muff u got)tab...use a hd clamp at your head pipe muff connection.....oh yea did you get a 7 deg adapter to keep the gasses off your brake ??

Thanks for the info, can anyone tell me what this "HD clamp" looks like or where to get one?

More importantly can you tell me where to get and what size 7 degree adapter you are talking about??

Sounds like I won't be riding anytime soon...

Just slide the header pipe into the HD muffler until it stops. This will leave 5/16" between the inlet of the muffler and the shoulder on the header pipe. Use the HD muffler clamp that belongs on the HD muffler and re connect everything to your Savage. The heat shield hides the joint where the header slides into the muffler. I did this a long time ago and it works just fine. Nothing comes loose and no leaks. No problems!

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Prophet_10

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Re: Harley muffler conversion, connection to heade
Reply #9 - 04/07/08 at 13:37:24

Problem SOLVED!

I ended up welding the dyna muff on - it was the only way I could do it without leaks.

I am pleased as piss with the result of the dyna conversion! I recommend it to anybody. I mean, its great that it looks so much better, and its great that it sounds so much better, but more importantly the bike performs so much better now. I have noticed more low end torque, no more clankity-clank at too-low RPM in a high gear.

I also spent some time last weekend removing the badges. I had a tape (remember those?) with [Rush] Hemispheres on one side and Signals on the other - I just kept flipping the tape and sippin' on few cold ones while getting all the adhesive off. The double-sided foam tape on the Boulevard badges were the hardest, but a bunch of adhesive remover and a ton of fingernail grease got the job done.

I also did my first oil change on saturday and it went pretty smoothly.

Heres a few photos:

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