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-   -   Installing Harley Fat Boy mufflers on XS11 motorcycles (http://www.xs11.com/forum/showthread.php?t=102)

xs11 06-20-2002 11:48 AM

Installing Harley Fat Boy mufflers on XS11 motorcycles
<H1>Installing Harley Fat Boy mufflers on XS11 motorcycles</H1><i>by Curt Marsh</i><HR NOSHADE>
Today, I finally got around to doing the project.

Installing Fat Boy mufflers on OEM 4 into 2 system on an '80 G.

H-D mufflers are readily available because H-D riders take off OEM systems, as soon as they can afford it, to get the "right" sound. Near new mufflers can be picked up for $30 to $40 per set on eBay. At swap meets they are usually cheaper on the last day because H-D riders don't want them.

The total time is about an hour (less, if you already have the adapter). Tools: Hack saw, 8 mm Allen socket (best) or wrench, 1/2 box wrench, a 10 mm box wrench, hammer and 2 X 4 block.
<ol><li>Remove the exhaust system and measure the diameter of the pipes.</li>
<li>Cut the OEM muffler just in front of the cross over pipe. This eliminated the cross over pipe. The pipe that was left is just a hair under 1 3/4" O.D. and double walled.</li>
<li>Install an adapter 1 3/4" I.D. by 1 3/4 O.D. by 4" long I.D. end goes over the muffler stub. I had to grind down the edge of the OEM muffler to start it. Then drove the adapter home with a board and hammer. This leaves the 1 3/4" O.D. to attach to the Fat Boy muffler.</li>

<b>IMPORTANT: Install the muffler, so the writing is upside down. It changes the angle of the bracket welded to the muffler.</b>

<li>The Fat Boy muffler has 2 bolts holding the OEM hanger plate. Remove the H-D hanger plate and install the Yamaha hanger plate from the OEM mufflers by the rear bolt. </li>
<li>Bolt on the headers, attach the muffler, bolt the hanger bracket into place.</li>
<li>Mark the hanger bracket angle. Remove the muffler and drill the second hole and put in the second bolt.</li>
<li>Install the muffler, again, and bolt the hanger bracket in place. </li></ol>It has a nice deep, mellow sound and a louder (but not H-D LOUD) than the OEM mufflers are. :( When you back it off in gear, it definitely says there something under this tank you don't want to mess with ;)

Idle may be just a little off. I'm going to wait a day or two and see if it needs adjusting.

I set aside half a day to do this project. If I had realized it was going to be this easy I would have done it a month ago ;)

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