How to Modify Harley Davidson Mufflers

Mufflers on Harley Davidsons can be modified to fit your personality.

Changing the muffler on a Harley Davidson is a common way of personalizing your motorcycle. The job of a muffler is to reduce exhaust noise, although a major part of their function is also superficial. Increasing the size of your muffler will reduce the noise of the engine. Traditionally, holes were placed in the mufflers of Harley Davidsons to make them louder, although increasingly different colors and sizes of mufflers are allowing for a greater range of custom mufflers.

Difficulty:

Moderately Easy

Instructions

1. • 1

     Select whether you would like to replace your muffler, or simply customize the one that is currently on the bike. Slip fit mufflers can be bought in a range of colours and designs, and can be easily fit to your bike. Painting a muffler can be a more difficult process than buying a new muffler to fit.

   • 2

     Clean your muffler of grease and dirt using a paint thinner and a wire brush. Gently sand it to remove any excess raised areas or stubborn dirt. After you are happy with the finish, begin painting your muffler, using paint designed for high-temperature painting, such as barbecue paint, or specialty high-temperature paint. When you are happy with the painting, switch your bike on for 15 minutes, then off for 15 minutes, and then on for 15 minutes, which will dry the paint without overheating it.

   • 3

     Wrap the muffler with heat wrap in the section nearest the engine. This need only be the 6 inches nearest to the engine, which will be too hot even for the heat-resistant paint.

   • 4

     Buy a completely new muffler, if you decide to completely modify your Harley. These can be bought in a variety of motorcycle shops, and online, although you should be sure to cross-reference the specifications of your bike with those of the muffler to ensure that it fits.

   • 5

     Drill your muffler to make a deeper sound, which will make you safer on the road, as well as make your Harley sound more like a traditional Harley Davidson. Detach the entire exhaust system and using a 1/2 inch bit on a drill, drill through the baffles. Drill the holes as centrally as possible, or your muffler will 'whistle' not 'roar'. Reattach the exhaust and the muffler.

   • 6

     Fit a new muffler to your bike. If it is a slip-fit muffler, then you will need to loosen the clamps on your existing muffler and undo the lock nut underneath your bike's brake pedal. Slide off the old muffler, and reverse the process to attach the new one. Ensure that all of the nuts and clamps are tight.