Question re: installing H-D slip-ons
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Joined: Nov 2008
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Question re: installing H-D slip-ons
New member here and happy new owner of an '03 RG (silver & black anniversary) - bone stock except for a chopped tour pack and highway pegs, in great shape, and only 9000 miles. I've only been out a couple of times so far, but quite a change from my '04 Sportster. I will try to post pictures soon.
I picked up a pair of H-D slip-on touring mufflers (65259-00) off ebay for a great price, but they didn't come with any hardware or instructions. I expect the installation should be fairly easy, but am hoping to hear from members that have done it and can provide any tips or steps (or even better, post a copy of the instructions). I'm no mechanic, but hopefully this is something I can do myself. My only real concern is that I need some hardware that didn't come with the mufflers?
Any info would be greatly appreciated -- I've been watching this site for some time while waiting to buy a touring bike and the info provided by members is invaluable. Thanks much.
I picked up a pair of H-D slip-on touring mufflers (65259-00) off ebay for a great price, but they didn't come with any hardware or instructions. I expect the installation should be fairly easy, but am hoping to hear from members that have done it and can provide any tips or steps (or even better, post a copy of the instructions). I'm no mechanic, but hopefully this is something I can do myself. My only real concern is that I need some hardware that didn't come with the mufflers?
Any info would be greatly appreciated -- I've been watching this site for some time while waiting to buy a touring bike and the info provided by members is invaluable. Thanks much.
Road Captain
Joined: May 2006
Posts: 720
Likes: 2
From: Kansas
welcome to the forum 
you can re-use your hardware, take off the saddlebags, soak the muffler/head pipe joint with wd40, loosen the clamps on the muffler neck, 9 1/16" wrench, remove the 2 bolts at the rear on the saddlebag support/muffler mounts, 1/2", wiggle, jiggle & pull till they come off, put the clamps on your new mufflers, orient everything like it was and tighten it all up, piece of cake!!
use some blue loc-tite on the muffler mount bolts under the saddlebags...
you can re-use your hardware, take off the saddlebags, soak the muffler/head pipe joint with wd40, loosen the clamps on the muffler neck, 9 1/16" wrench, remove the 2 bolts at the rear on the saddlebag support/muffler mounts, 1/2", wiggle, jiggle & pull till they come off, put the clamps on your new mufflers, orient everything like it was and tighten it all up, piece of cake!!
use some blue loc-tite on the muffler mount bolts under the saddlebags...
Road Captain
Joined: May 2006
Posts: 720
Likes: 2
From: Kansas
You're welcome
sometimes you have to really get after them to get them off... I push downward pretty hard to "open" up the neck a bit, helps them come off easier, also take some emery cloth to clean off the carbon & rust on the head pipes and the inside of the replacement muffler neck, some more wd helps there too...
sometimes you have to really get after them to get them off... I push downward pretty hard to "open" up the neck a bit, helps them come off easier, also take some emery cloth to clean off the carbon & rust on the head pipes and the inside of the replacement muffler neck, some more wd helps there too...
Seasoned HDF Member
Joined: Apr 2008
Posts: 8,051
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From: Florence, MT (Bitterroot Valley)
Make sure you don't have any leaks when you reinstall. New clamps are always best, and cheap. If you have concerns about leaks a very thin layer of heat treated silicone around the header where you slide the muffler on, and clamp it down will solve your problem.. Good Luck.
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Road Captain
Joined: Oct 2007
Posts: 516
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From: Ontario, Canada home of the TAX YOU TO DEATH LIBERALS
Be careful pushing up and down on the mufflers as you might crack the rear header pipe if you get too giddy. Rubber band style tension clamp wrapped around the muffler helps greatly in trying to twist the muffler back and forth as you exert rearward pressure. The rubber on the tension strap does not mark your chrome. Another tip is to lube the mounting rubbers on the brackets that attach to the saddle back brackets. Also, if you get a rattle from the pipes in this area when you start it up, loosen the clamps and twist the muffler SLIGHTLY so that they are slightly offset in the brackets. Good luck and enjoy
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Great additional info - thanks again, all. Sounds like a very doable project, although I am on the fence now about doing it myself or paying the dealership, since I'm going to have them do the remap in any case (to go with the slip-ons and AC kit). Would be one thing if I could do it all, but they will be charging me for the remap anyway....we'll see.