How to Modify a Harley Touring Muffler
Harley-Davidsons are famous for having a wide range of customization options, allowing owners to put their unique personality into their motorcycles. The same is true of the mufflers, which have become important areas for customization. Although the original purpose of the muffler was to reduce the noise of the exhaust, Harley-Davidson owners regularly drill, paint or replace their mufflers to make their bikes more unique. You can modify your Harley muffler without a great deal of technical expertise.
- Moderately Easy
- Steel wool
- Paint thinner
- 1/2-inch drill bit
- High heat paint
- Heat wrap
Clean the muffler using steel wool and paint thinner. This will remove dirt and grease, although sandpaper may be needed to remove stubborn stains. Once it has been cleaned, then it can be painted or drilled.
Drill the muffler to create a deeper noise for your engine. Remove the entire exhaust from the Harley and place it in a vice, wrapping the exhaust in rags where it is held in the vice to minimize scratching. Using a 1/2-inch drill bit, drill two holes in the rear baffler, centering the holes to make a "roar," not a "whistle." Test the noise of the two holes before drilling further, since too much noise may violate noise level laws. Sand the muffler if you intend to paint it after drilling.
Paint the muffler using high heat paint, which can be bought from hardware stores. Barbeque grill paint will also work. After painting, use a heat wrap to cover the 6 inches nearest to the engine, as this will be exposed to the highest heat. To gently dry the paint, run your motorbike for 15-minute cycles, with 15 minutes on and 15 minutes off.
Buy a new muffler for a full modification. These can be bought online, or at a Harley-Davidson store. Be sure that the specifications of the muffler fit the Harley you are installing it on, or it may not fit. Loosen the exhaust clamps and remove the locknut under the brake pedal. Reverse this to insert the new exhaust, and be sure to tighten all the nuts and clamps.