Exhaust muffler keeps coming off

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Nov 9, 2013 | 12:09 PM

#11

Imold

Seasoned HDF Member

Joined: Jul 2011

Posts: 27,097

Likes: 4,676

From: Frozelandia, Minnysota

Quote:

Originally Posted by Rico Rose

Out of round because it was tightened too tight.

Try a new torca clamp they are only $8 at the dealer. And don't overtighten.

Ditto on too tight. I replaced one last week, thought that 45-65 ft lb torque (manual) was awful high, so I've been installing them on the low side, never had one get loose. But this clamp had been re-used at least twice before, and snapped before it even hit 45. Even a new one would probably break before it felt like it "bottomed out", if someone tried to install it that way without a torque wrench.

Nov 9, 2013 | 12:40 PM

#12

2black1s

Elite HDF Member

Joined: Nov 2010

Posts: 3,846

Likes: 173

From: Simi Valley, CA

Quote:

Originally Posted by Tirpitz

Use a piece of steel, thin and half moon shape as a shim and try that.

I've done this and it works although I've done nearly a full circle, not just a "half-moon". You can find some thin (< .010") galvanized sheet metal at any building supply, i.e., roof flashing, gutters, ductwork, etc. Just cut to fit. If you have this stuff laying around and the tools to cut and shape it it's worth a try. If not, just go buy some new clamps.

And as for the comments on distortion from overtorqueing, it ain't gonna happen. The clamp's design with the saddle that you tighten against will not allow the clamp to over compress or to strecth beyond its design limit.

Another post mentioned a torque value with an upper limit of 65 ft. lbs. That has to be a misprint as 65 ft. lbs. is way too high for any grade of 3/8-16 bolt. 40-45 ft. lbs. for an upper limit would be more like it.

Nov 9, 2013 | 12:53 PM

#13

MURPHCC1

Club Member

Joined: Apr 2013

Posts: 5,857

Likes: 3,841

From: Cape Cod

had the same problem too........wasnt the clamp or out of round......it was the collapsing end of the muffler itself, where it has the slots at the very end, SE pipes had the little tab that fits into the other side of the tip, it was getting hung up by not being square and going in there correctly, ground it down and it slides in nice and tight now!!

Nov 9, 2013 | 03:07 PM

#14

Imold

Seasoned HDF Member

Joined: Jul 2011

Posts: 27,097

Likes: 4,676

From: Frozelandia, Minnysota

Quote:

Originally Posted by 2black1s

...
Another post mentioned a torque value with an upper limit of 65 ft. lbs. That has to be a misprint as 65 ft. lbs. is way too high for any grade of 3/8-16 bolt. 40-45 ft. lbs. for an upper limit would be more like it.

I mentioned it, it's in my manual. But I agree with you, seems way too high for the size bolt, why I only torque to the bottom limit, 45 ft lbs.

Nov 9, 2013 | 07:38 PM

#15

scooter1128

Road Captain

Joined: May 2009

Posts: 717

Likes: 18

From: perry, fl

i just had this happen when i changed my mufflers. bought new clamps, problem solved

Nov 9, 2013 | 10:49 PM

#16

ALUCARD19

Road Master

Joined: Oct 2013

Posts: 924

Likes: 0

From: Elgin IL

Ditto Above I'm a tool/die maker new clamps every time I change mufflers, cheap price to pay.

Nov 9, 2013 | 11:29 PM

#17

jackstrr

Road Warrior

Joined: Nov 2006

Posts: 1,671

Likes: 11

From: sequim, wa

new clamp

Nov 9, 2013 | 11:45 PM

#18

Woodchuck

Road Master

Joined: Oct 2006

Posts: 832

Likes: 6

From: Vermont

My left side muffler slipped off a couple of times early this spring. I took off the used clamp and "temporally" replaced it with two stainless steel worm gear type hose clamps until I could get to the Harley dealer to buy a new one. The new clamp is still in the bag since the hose clamps are holding like a champ.

I placed one right at the connection between the muffler connection and the pipe and the other one just behind it. I used a socket on the screw rather than a screwdriver and sequentially torqued down each clamp. I tightened the front one to the point that the worm screw jumped out of the clamp slot but was able to retorque it.

The next time the muffler comes off for maintenance I may use the new clamp but the hose clamp method seems to be working better for me. It seems like the run on torque for the Harley clamps is a bit much even when new.