Samson True Dual Install Issue(s)...Installer Error?
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Cruiser
Joined: Oct 2010
Posts: 196
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From: Bloomington, IL
Samson True Dual Install Issue(s)...Installer Error?
So I installed the Samson Duals that I got from Dr. V-Twin last week. The right side was smooth sailing, but I have had issues with the left side. The bracket rubbed the swingarm when I mounted it, so I threw some spacers in there to take care of it. The two holes on the bracket for the muffler also do not line up. Also, if you notice, I could not get the muffler & heat shield to meet together like I did the right side. Finally, the left side is lower than the right side muffler by a couple inches. I installed everything loose and then started tightening at the end like instructed, but I still couldn't get everything to jive together the way I think it should. This is my first exhaust install, so it is quite possible I did something really dumb. I've attached some pictures to see if anyone has any suggestions. It still isn't nice enough here for consistent riding, so I'm not concerned about this delaying me. I just want to get it corrected.
Road Master
Joined: Feb 2008
Posts: 1,012
Likes: 1
From: SoCal
I believe this is gonna be installers error 
. No but really, I had similar issues the first time I installed a set of Samsons. There is a learning curve when installing this system.
I'll address the space between the head shield and muffler. You've got to move both pieces (muffler and head pipe) together to get them to meet. If you haven't already tried...with everything still lose, move the head pipe (the one that flows over the primary) into the muffler....instead of moving the muffler into the head pipe. You should be able to get most of that space out this way.
This will almost feel like your lifting the pieces up as you remove space. Grab both sides and move them up and together, or down and together. That's how I do it...and it's worked every time.
It is important that all connections remain lose when you do this: bracket to muffler, bracket to frame, muffler to head pipe clamp, head pipe to small head pipe to the rear jug clamp, and the head pipe at the jug.
I think you'll see that much of the space will be removed doing this...and at the same time probably bringing the height of that pipe closer to the other side.
Once you've got them where you want them, tighten it all up from the back of the bike to the front....so from the rear muffler bracket to the jug.
I'll let others chime in on the rest...and also correct or clarity anything I just wrote.
. No but really, I had similar issues the first time I installed a set of Samsons. There is a learning curve when installing this system.I'll address the space between the head shield and muffler. You've got to move both pieces (muffler and head pipe) together to get them to meet. If you haven't already tried...with everything still lose, move the head pipe (the one that flows over the primary) into the muffler....instead of moving the muffler into the head pipe. You should be able to get most of that space out this way.
This will almost feel like your lifting the pieces up as you remove space. Grab both sides and move them up and together, or down and together. That's how I do it...and it's worked every time.
It is important that all connections remain lose when you do this: bracket to muffler, bracket to frame, muffler to head pipe clamp, head pipe to small head pipe to the rear jug clamp, and the head pipe at the jug.
I think you'll see that much of the space will be removed doing this...and at the same time probably bringing the height of that pipe closer to the other side.
Once you've got them where you want them, tighten it all up from the back of the bike to the front....so from the rear muffler bracket to the jug.
I'll let others chime in on the rest...and also correct or clarity anything I just wrote.
Last edited by JayDee5150; Mar 6, 2011 at 01:17 PM.
Road Warrior
Joined: Jun 2010
Posts: 1,829
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From: OC,NY
Ice I had some of these issues as well.First make sure you are using the right brackets for each side.Never had to use spacers or rubbing the swing arm issue.These Samson Duals take some working with to get them correct.The height is an easy fix. Loosen both muffler brackets.You may need to push the right one down a bit and pull the left one up to make them even.When you get them even have some one hold the mufflers. Because when you retighten the muffler brackets they are going to want to move around again .Once you tighten one check the other.I did this with a tape measure bottom of pipe to Floor.You want to make sure the bike is level (on a Jack,Lift) not on the kick stand.The Heat shield on the left side I found every time I tightened the last clamp (closest to the muffler) It pulled the shield away from the muffler creating that gap.Position the shield where you want it .Then tighten the first 2 clamps.Than just tighten the last one as much as you can until it starts to pull the shield away from the muffler and stop.It isn't going any where with the first 2 nice and snug.What I did to get the holes on the muffler to line up was.First install the muffler loose into the cross over pipe.Before you attach the muffler bracket to the frame,First thread the two bolts into the muffler loose. Than attach the bracket to the frame. It worked for me. Good Luck Bro.
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Cruiser
Joined: Oct 2010
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From: Bloomington, IL
Thanks for the feedback. It'll be a couple weeks before I get a chance to tear back into it. I did find that I had a lot of difficulty getting the header bolts tightened in such a confined space. Are there any particular wrenches you used to get the U-tube fastened? I have a pretty good selection of tools, but I've never worked in such confined spaces that are found on a bike.
Cruiser
Joined: Oct 2009
Posts: 109
Likes: 0
From: Oklahoma
I had same problems as your havings and what JayDee says is dead on. One thing I might add and had to do on mine to get them to line up is after you get left side set if you still have alignment issues loosen everything on the right side and put some pressure pushing down on the end of the muffler and start tightening from the front to the rear. An extra pair of hands is useful too.
Edit: What Malingerer said.LOL was writing my post when he posted. Good luck bro they will be worth the effort when your done.
Edit: What Malingerer said.LOL was writing my post when he posted. Good luck bro they will be worth the effort when your done.
Last edited by trickin addixion; Mar 6, 2011 at 01:41 PM.
Thread Starter
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Cruiser
Joined: Oct 2010
Posts: 196
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From: Bloomington, IL
Thanks guys, sounds like I just need to keep plugging away. I am still worried about the bracket contacting the swingarm though without using spacers. This shouldn't be affected by anything else. This may be a dumb question, but do I have the bracket on correctly? To me it didn't look like there was another way, but I just want to rule out all possibilities before going too awful far.
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Road Master
Joined: Feb 2008
Posts: 1,012
Likes: 1
From: SoCal
The bracket hitting your swing arm is throwing me for a loop...big time.
It looks like you have it on correctly....can you take a few more pics of the bracket and post them up...close ups of where it's mounted to the frame?
I'll try and take some pics of mine if I can and post them up for you.
I gotta say, just a quick look at the photos you have up already, it looks right. You should not need any spacers.
Maybe the Samson Sponsor on the forum will chime in on this tomorrow.
It looks like you have it on correctly....can you take a few more pics of the bracket and post them up...close ups of where it's mounted to the frame?
I'll try and take some pics of mine if I can and post them up for you.
I gotta say, just a quick look at the photos you have up already, it looks right. You should not need any spacers.
Maybe the Samson Sponsor on the forum will chime in on this tomorrow.
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Thread Starter
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Cruiser
Joined: Oct 2010
Posts: 196
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From: Bloomington, IL
That is all the pics I have right now. Bike is in my dad's shop & it is about an hour from my house. Won't be back that way for a couple weeks. Hopefully, I can get some feedback from Samson and go from there. I will be investing in some shallow sockets and a couple new flex adapters to help with the manifold bolts before I try again. That rear U pipe was a PITA.
Cruiser
Joined: Oct 2009
Posts: 109
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From: Oklahoma
Thanks guys, sounds like I just need to keep plugging away. I am still worried about the bracket contacting the swingarm though without using spacers. This shouldn't be affected by anything else. This may be a dumb question, but do I have the bracket on correctly? To me it didn't look like there was another way, but I just want to rule out all possibilities before going too awful far.
