How To install Harley Mufflers-GL1100 (SOLD!)

Roady

I have two extra sets of H-D mufflers that can be easily adapted to fit most GoldWings. The chrome quality on these is absolutely stunning. I'm asking $25 for each set plus shipping cost from 62223. Box size is 24x10x4; the Sportys weigh 12.5 lbs and the Dynas weigh 14 lbs. (UPS to Phoenix is about $18.)

Shown below is a set of 2003 Sportster mufflers installed on my bike.

The '02 Sportster mufflers (below) are 19" long and were on the H-D for about 5k miles.

The one with the big hole in the mount fits the Wing's right side and is flawless. Some issues with the one for the left side: 1. It has two small dings on the bottom (wouldn't show in the pics), 2. The stamped in lettering is on the top, outside of the mount (true on all of these since they both mount on the right on H-Ds, 3. There is a dimple on the top at the rear (also true on all of these).

To mount the Sportys on my bike I first removed the old mufflers and headers (be sure to get the "squash" washers out and replace them with new ones). Then, carefully cut the chrome covers off the headers and cut and grind the header exits to get to good metal. Get two 4" x 1-3/4"O.D. pieces of muffler pipe at AdvanceAuto. Temporarily remount the headers, slip the bolt thru the new muffler and onto the stock mount. Line it all up and trim the 4" pipe to the correct angle and length. Tack weld it to the header. Remove the header and put a good weld around the joint. Tack the chrome covers back on the headers. Put in the new squash washers and mount everything.

With the mufflers mounted directly to the stock mounts, the left one was too far out and too high. The centerstand also stuck it. So I made a bracket from a 1" piece of strap steel. It's now about 1/2" too low at the end and still maybe an inch too far out. I also added a rubber-baby-buggy-bumper to catch the centerstand. The experiment continues Rolling Eyes

Initially I used radiator clamps at the junction but ended up buying a set of '02 Sportster clamps from the H-D dealer. $8 each.

They sound great, rumbly but not too loud, YouTube: Winnie with H-D mufflers.

The Dyna mufflers are 18-1/2" long and were taken off the H-D before it was ever started. Inside they are not a bit dirty and outside they are flawless.

I have never mounted Dynas but it looks like you'd need to fashion some mounting brackets for them. Perhaps the stock muffler brackets could be used for these.