Slip on Muffler Removal, tips and tricks

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Slip on Muffler Removal, tips and tricks

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Benno
4 years ago

Gents, am looking for any tips or tricks for removing a set of slip on mufflers that I reckon have been on my Evo Dyna since the late 90's. I am trying to take the old girl back to as close to original as I can, I recently scored a set of S&S Tapered Turbos to go on the old girl to get the standard look back and I don't want to damage the headers in any way. I know these fucking things are going to hard to get off, so any tips or tricks you guys have would be greatly appreciated.
Benno.

As new

steelo
4 years ago

Hi Benno.
Good on a for taking it back to stock looking. Looks like it has nice chrome heat shields. Spray penetrating oil, (I don't know if WD40 strong enough) on all the bolts and fittings.
Leave overnight or as long as you can bear. Undo what you can including heat shields. Spray more, leave.
Start at the back and wriggle the end of the tail pipe. Spray more at joint if required. Wriggle spray. Repeat.

If that fails, cut em off with a blow torch!

fatbat
4 years ago

As above.

Also if you have a lip to work with, wedge something against it and start tapping with a hammer. You can also use a mallet (and a block of wood) to tap the muffler forward (yes forward) to break its seal. Once the initial seal is broken it’s easy to twist and pull back. Flood as much as you can with lubricant. Wd40 has done the job for me with an older bike than yours

beaglebasher
4 years ago

As the boys have said Benno try the wd40 but start spraying it on now and tackle the the job next week
Give them a good tap with a hammer and a dolly every other day .
You will probably get to the stage where brute force and ignorance is required.
And dont forget to swear a lot. Buy a couple of the header gaskets just in case you end up taking them off

steelo
4 years ago

How will that help BB?

Benno
4 years ago

Lol, the concenses seem to be, put plenty of pidgeon piss on the join area, soak it in it for at least a week. Try and move it back and fwd to break the seal, agree completely , am thinking of trying a filter strap on it after a couple of taps. And if that don’t work hit it with brute force.
No finess with you pricks is there, haha.
Thanks guys, all suggestions are welcome, really don’t want to damage the headers, knew their would be some experience among you lot.
Benno.

Soapbox2627
4 years ago

WD40 or CRC are "ok" as a release agent, lubricant and water repellent

Try "Yield" it is a bit more expensive but that is its job
if heat is not possible you could also go the other way and try some "freeze release"
see the links
if you don't want the old mufflers, cut them off with a hacksaw then either wedge (screwdriver) them out off the headers from the inside or cut slits with a dremel to loosen them enough to pull off

beaglebasher
4 years ago

I had a job at work today which was similar. It was a 2 inch rubber hose that had been on there for at least 3 years.
Because I have more experience than most ( especially steelo ) I chose the brute force and ignorance option.
I pulled it off with a half ton chain block .
Too fukin easy.

Humbug likes this post

fatbat
4 years ago

Shame bloodog hasn’t posted on this topic. He’s a big fan of using a claw hammer for any and all tasks. And nothing beats an angry red head with a hammer.

In terms of force used, I got the fattest and heaviest mate I have to sit on the bike whilst I used a hammer, mallet and brute force after flooding with wd40 and leaving for a while. Without a big fat cunt sitting on my bike it might have fallen over. I just fed him beers and he was happy as a lark sitting on his arse whilst I swore like a trooper as bb suggested. It worked

bloodog
4 years ago

Never far away FB
O and that's not a hammer steelo

and by the way last post on this topic shows I have 2 skills for working on a bike
1. hammers
2. Fat cunt

fatbat and Ratbob like this post

Ratbob
4 years ago

One question Benno “do you want the old pipes?”
If the advice above fails, drill a hole right through the buggers, anywhere you can insert a bar through to give you sort of a T grip, probably in the last few inches of the muffler, gets em off easy.

bloodog likes this post

beaglebasher
4 years ago

Dont mean to hijack your thread Benno but I cant be bothered starting a new one.
I have a 2002 model 88 inch twin cam that has almost 60 k on the clock. I have never opened up the cam cover and had a look but I intend on doing that before I take the bike up the coast at Christmas. I dont know if it is my imagination or not but I sometimes hear a slight rattle that I havent heard before. I had the primary cover off a while back and all was good in there.
My question is when the cam cover is off, can you see everything or do you need to go further and is there any special tools needed?
The bike has been reasonably well maintained and it runs like a train . Any tips will be appreciated.

fatbat
4 years ago

Beagle, your version of the twin cam are prone to cam tensioner shoe failure. Consequences can be catastrophic. I think it’s supposed to be checked before 60k km so get in there and inspect. Can be upgraded to better system whilst you’re in there. Heaps of info on the net about this. I dunno too much personally as they changed the cam tensioning from 2007. Start researching it mate. Check out:
https://www.lawabidingbiker.com/73/

Options are to inspect/change your shoes, or replace to a gear system which will last forever. No matter which option you go with, you’re in far enough to change the cams and cam bearings but need to either make/borrow/buy a bearing puller I think. Most of the other stuff can be done with standard tools I think

robnicko
4 years ago

the slipons should have a slit where they join the head pipe that closes when clamp tightened
remove shields and the clamps completely, spray the lubricant and use a large flat blade screwdriver to open up the slit a little bit by twisting sideways
then as Fatbat said, tap in a little to break seal then twist as pulling them back

beaglebasher
4 years ago

thanks for that fatbat.
Hopefully I should be able to find the time to have a look at the weekend.

dicko
4 years ago

Quoting beaglebasher on 17 Nov 2020 09:40 AM
Dont mean to hijack your thread Benno but I cant be bothered starting a new one.
I have a 2002 model 88 inch twin cam that has almost 60 k on the clock. I have never opened up the cam cover and had a look but I intend on doing that before I take the bike up the coast at Christmas. I dont know if it is my imagination or not but I sometimes hear a slight rattle that I havent heard before. I had the primary cover off a while back and all was good in there.
My question is when the cam cover is off, can you see everything or do you need to go further and is there any special tools needed?
The bike has been reasonably well maintained and it runs like a train . Any tips will be appreciated.

Yes , there is a changeover for 88's to hydraulic , like the 96 engine , or gear drives. some replaced the shoes with different material.
My 88 bike was checked at 75.000k and shoes were about half worn. replaced anyway while in there.
Not all bikes had premature failure of the shoes.
It was blamed on a set of chains which were a bit rough at manufacture.
If yours is rattling its time to check and replace with one of the options.
I personally now wish I had opted for gears.

Benno
4 years ago

Quoting robnicko on 17 Nov 2020 10:07 AMedited: 17 Nov 2020 10:08 AM
the slipons should have a slit where they join the head pipe that closes when clamp tightened
remove shields and the clamps completely, spray the lubricant and use a large flat blade screwdriver to open up the slit a little bit by twisting sideways
then as Fatbat said, tap in a little to break seal then twist as pulling them back

I can only hope they come off as easy as that after 20 years Rob.

Benno
4 years ago

Quoting beaglebasher on 17 Nov 2020 09:40 AM
Dont mean to hijack your thread Benno but I cant be bothered starting a new one.
I have a 2002 model 88 inch twin cam that has almost 60 k on the clock. I have never opened up the cam cover and had a look but I intend on doing that before I take the bike up the coast at Christmas. I dont know if it is my imagination or not but I sometimes hear a slight rattle that I havent heard before. I had the primary cover off a while back and all was good in there.
My question is when the cam cover is off, can you see everything or do you need to go further and is there any special tools needed?
The bike has been reasonably well maintained and it runs like a train . Any tips will be appreciated.

Plenty of videos on youtube BB so you get an understanding of what is required, I just done the cams in my 07 dyna @ 50k, pads were worn down maybe 1/8 - 1/4". For peace of mind with the k's on your ride, I would be doing them while your in there.

Airhead
4 years ago

Quoting bloodog on 17 Nov 2020 05:28 AMedited: 17 Nov 2020 05:31 AM
Never far away FB
O and that's not a hammer steelo

and by the way last post on this topic shows I have 2 skills for working on a bike
1. hammers
2. Fat cunt

This is my way of doing it too. One four pounder.

Plus I need about eight full strength beers, or, almost two bottles of wine. Sort of either or. This gives me patience for the long wait in the Emergency Department waiting room after the cold chisel slips and cuts half of the way through my left index finger. Not to worry though, the pipes will still be there tomorrow so I can have another go while I am less dexterous.

beaglebasher
4 years ago

Quoting beaglebasher on 17 Nov 2020 09:40 AM
Dont mean to hijack your thread Benno but I cant be bothered starting a new one.
I have a 2002 model 88 inch twin cam that has almost 60 k on the clock. I have never opened up the cam cover and had a look but I intend on doing that before I take the bike up the coast at Christmas. I dont know if it is my imagination or not but I sometimes hear a slight rattle that I havent heard before. I had the primary cover off a while back and all was good in there.
My question is when the cam cover is off, can you see everything or do you need to go further and is there any special tools needed?
The bike has been reasonably well maintained and it runs like a train . Any tips will be appreciated.

Quoting Benno on 17 Nov 2020 09:22 PM
Plenty of videos on youtube BB so you get an understanding of what is required, I just done the cams in my 07 dyna @ 50k, pads were worn down maybe 1/8 - 1/4". For peace of mind with the k's on your ride, I would be doing them while your in there.

Cheers Benno. I will have a look on you tube before I tackle it. How long did it take you to do the job on your bike?

Topics

1/2

Slip on Muffler Removal, tips and tricks

Slip on Muffler Removal, tips and tricks

Benno

steelo

fatbat

beaglebasher

steelo

Benno

Soapbox2627

beaglebasher

fatbat

bloodog

Ratbob

beaglebasher

fatbat

robnicko

beaglebasher

dicko

Benno

Benno

Airhead

beaglebasher