'86 Muffler removal & replacement

[chicagorandy]

I am looking to replace my right side muffler and tailpipe with an OEM 2nd hand one I got from the original owner years ago. The last section of the right rear tailpipe was broken off by the previous owner. Are there any tips/tricks involved with this project or is it as straight-forward as it seems to be in the parts drawing? Namely two bolts attaching it to the frame and two clamps (1 bolt each) to remove it from the header and center crossover?

I was able to source NOS gaskets off e-bay and Partzilla.

Do both sides have to be loosened first or can I just undo the right side?

Thanks in advance for any guidance.

[Nails]

Straight-forward; but the bolt holes (hanger) can be difficult to line up, especially if your headers bashed into speedbumps or whatever.

You can remove the tailpipe without messing with the rest of it. It just slips onto that collector thing under the engine. You might want to take other stuff off to see what you're doing, like the saddlebag for starters. But I've slept a few times since I did this and don't remember.

[chicagorandy]

Because of the rear cross-over connection, I had to remove both mufflers to replace the right side. DOH!!

As I was working on the bike solo and you pretty much have to be on the ground on both sides of the bike at the same time to try and slide both mufflers into the headers AT THE SAME TIME and not let the center separate??........ Oh it was a real jolly 60 + minutes of grunting, swearing and threatening to set the durn thing on fire right there in the alley by my garage. And yes, aligning those hanger bolts was a real character builder - lol

But Eureka! The job is done and now I can do the more mundane task of checking tire pressures. Thankfully my latest Amazon purchase arrived this afternoon to make it MUCH simpler to get a gauge on those 90 degree Shrader valves.

https://www.amazon.com/gp/product/B075T ... UTF8&psc=1

[Nails]

I forgot about that separate cross-over. But like you, I got it by myself.

When I finish this shop construction, I plan to fab on some stock Harley mufflers. No cross-over, and about a foot shorter. I don't think I'll have too much noise or any performance issue ... but vamos a ver.

[GrandpaDenny]

I plan to fab on some stock Harley mufflers

Oh. my. god.

Somebody restrain the man, he's gone over the edge.

can't wait to see and hear the result.

[Nails]

Somebody restrain the man, he's gone over the edge.

Oh keep your pants on. They're stock pipes, not the loud pups every Harley actually has. I bet they'll be quieter than Cobras -- hope so. I also hope I'll actually be able to hear shift points.

It looks like I can start with some SS stock with a 45-degree bend, cut it in the middle, turn one side around 180-degrees, and weld it back together in an S shape. The idea is to offset the pipes out from under the bike. And it isn't exactly 180-degrees because the pipes will flare out a little. With a lift table, I should be able to tack it up in situ.

Yeah, I'll tell you all about it. Sometime after I finish the damn shop, that is.

(Once I used Harley-sourced jets in a dirt bike. Boy did that bike fly!)

[GrandpaDenny]

Oh keep your pants on. They're stock pipes, not the loud pups every Harley actually has.

I didn't say anything about loud pipes. Just that they're *shiver* HARLEY pipes. And... not every HD has loud pipes. It only seems that way.