Muffler install problem
Grand HDF Member
Joined: Mar 2007
Posts: 4,917
Likes: 262
From: Deep in the heart of New Jersey
Jabmike, I kinda did the same thing on my bike the beginning of last summer, but different problem. My left side muffle would keep sliding off the head pipe. What a pita, I changed the clamp and that didn't help. So I used the same expander you did on the head pipe, a little at a time until if felt tighter. marked the pipe so I could tell if it started to move, almost a year later still on the mark.,,
Seasoned HDF Member
Joined: Jan 2011
Posts: 157,119
Likes: 56,617
From: Michigan 15 Minutes East Of Hell
This is great tool ... but ... use with caution, especially on inlets with a notch / split on them
Tourer
Joined: Apr 2019
Posts: 382
Likes: 217
From: Wisconsin
Wrap some fine emery cloth around the outside of the tip of the header pipe and clean it up, then do the inside of the muffler. Then lube and reinstall. If it still gives you trouble but has started to go on, a rubber mallet or a piece of wood and a hammer will persuade it to cooperate
I am going thru this now, as I picked up a used pair of mufflers. I used a Dremel like air tool with a small diameter wire brush wheel on the inside of the muffler itself. Then took a 8" piece of emery cloth and looped it over the header pipe and worked it back and forth. I wiped a paper towel with some WD40 on it and it went on much easier that before but still too a small bit of persuading.
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