S40 Suzuki Boulevard Exhaust Upgrade heckmechanic

12 Фев 2015 | Author: | Комментарии к записи S40 Suzuki Boulevard Exhaust Upgrade heckmechanic отключены

Vehicular Performance, Restoration, and

S40 Suzuki Boulevard Exhaust

Posted by mechanic on June 18,

Are you tired of your S40 Suzuki humming like a sewing This upgrade will get you in no time.

In this project we the stock muffler of a S40 Suzuki with the slip on muffler a Harley-Davidson Dyna motorcycle.

My owns this vehicle and to enhance the auditory output of the after some one tried to on him. I must say I have with him and his motorcycle, for all intents and was silent at road speeds. the people merging on him.

S40 Boulevard Before

So he did some and found out that a stock Dyna muffler will fit perfectly on an S40 Boulevard with modifications to the OEM equipment.

Fortunately, there is a local dealer that sells parts on the cheap so he was able to get a muffler for 25 bucks. This is less than the Suzuki

Stock on top, Dyna on

In the image above you can see the Dyna mocked up before it is put on the bike. The Pipe is slimmer but has much throughput. It also weight less than the stock S40 Pipe.

Tools Needed:


Metric tool set allen wrenches, and

Sheet cutters.

Materials Needed:

bit of sheet metal,

Two bolts about 2 inches with flat washers, and lock nuts. We used US because that’s what we had on

The first step is to get the original assembly off the bike. Start by the two bolts from pipe connect it to the engine head. will prevent any possible on the seal when taking the off.

Next, remove the heat shield by removing the two from the right side controls. You do not have to remove the controls to do this. The heat should slide off the posts.

the nuts on the foot controls to them from moving. get them on there for safe They will be taken off

After the heat shield has removed, unscrew the two bolts the muffler to the muffler stabilizer. this the pipe should right off with a little

S40 Suzuki Boulevard Exhaust Removed

Suzuki Boulevard S40

Now that the pipe and is off the bike unscrew the clamp the Suzuki muffler to the exhaust and remove it by pulling it off the pipe. You now have a exhaust pipe and a

This would be an excellent to put the stock Suzuki muffler in one and the Dyna muffler in the other You can feel the serious weight in the two. Also view the size difference.

The throughput of the Dyna muffler is greater than the Suzuki.

If you now both of the mufflers in your you will see a difference in how they are The Suzuki muffler has integrated that fit into the muffler on the bike. The Dyna muffler has a that bolts are inserted and slide through.

This is the metal grinder comes in. If you your two replacement bolts and to insert them into the Muffler you will find the head on the bolt is too tall. solution, grind about 1/2 of the off of the bolt.

Every so often the grinding process, try to slide the into the Dyna muffler. it can be inserted and slide in the rail you are

Now that the bolts have placed in the Dyna muffler it to the muffler support of the Suzuki. tighten them all the way. a little play in the bolts to for adjustment.

Now that the new muffler is on the its time to make a coupler will fill any gaps the muffler and the exhaust pipe. We a bit of sheet metal to fill the spacing gap between the muffler and the pipe.

Muffler to Exhaust Seal

With the muffler in slide the fabricated gasket the muffler. Be sure to leave of the gasket out of the muffler to insert the exhaust pipe.

Inserting the gasket into the

With the gasket in place on the slide the exhaust pipe the gasket and attach the pipe to the head of the engine.

Suzuki Boulevard S40
Suzuki Boulevard S40
Suzuki Boulevard S40


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