[Zman76]

First Of All, HELLO! This is my first post as I am a newbie. I am a newbie to the wonderful world of motorcycles as well. I decided after many years to finally take the steps toward being a safe and responsible motorcycle rider. Well, I may have gone about it all backwards but I bought the bike before the license! I do have my permit and am scheduled for the safety course so, it's all good. Anyway, back to the topic at hand. I purchased a 1980 CX500 Custom with over 40,000 miles, yeah I know. Well, it is in better shape than you might expect. The biggest issue I am having right now is the mufflers have been horribly modifed or at least I think so! A previous owner decided to knock out the end baffle or cap and now it is wide open back there. This is of course affecting performance. It bogs down a little but mostly back fires. I have searched high and low on the net for a cheap fix to this problem bk I don't really want to refurb this bike or pay more for the pipes than I did the whole bike! What solution could be done to restore the mufflers to as close to original as possible w/o buying all new ones? Thanks!

 

[Zman76]

I see your version of cheap isn't exactly my version....ha ha hah! Do you think I would have to rejet with these?

 

[Zman76]

OK, so I got some HD Dyna mufflers, $10 on eBay ...awesome! Anyway, I had read previous forum from old site and thought it indicated these would bolt right up w/o modification. Well, the current hanger bracket definately will NOT mate up with the Dyna muffler. The Dyna muffler bracket is a good 3-4 inches further back than the stock. So, will need to get a bracket made. I don't currently know of anyone that could do this for me so, if any of you have made one and it works, please give me details on size and such of the bracket. I would really love to buy something if someone would be willing to make some for this purpose. Let me know.

 

[Zman76]

So, the nightmare for the "easy" Harley muffler has begun. The fun started with trying to remove the OEM mufflers. They had become one with the H-Box! They were rusted tight and needed much persuasion and cursing to free them. As you can see after an hour or so I finally managed to get them free. Now, the dilema of fitting HUGE HD Dyna mufflers to a bike that was clearly never meant to handle such beasts. I know I am beating a dead horse here but I really need some input as to what in the heck to do with a bracket set-up. Please include any ideas and provide as much detail on material and configuration as possible, pics of your bike modified in a similar way would be great!



The OEM muffler had snapped off inside the H-box and I had to PB blast it to death and dig it out.

[attachment=267:OEM LH Muffler.jpg]



This was the fun one!

[attachment=268:OEM RH Muffler.jpg]



The bracket will need to be 7" to accomadate the Dyna bracket

[attachment=269:Side View New Muffler.jpg]



You can see the position of the muffler, not much clearance for nuts to the swing arm!

[attachment=270:Top View New Muffler.jpg]