Stallion Exhaust

[Mattel]

I need to quiet my Stallion. If someone had figured out a muffler to use can you post a picture of it for me? I am trying to get this work done this week so I can ride it to bike week.
I think someone put on an oval muffler but I just don't see how it could fit.

 

[Papa Zook]

I did this exact mod 6 months back but wasn't happy with the ground clearance and I wanted duals rather than the single exhaust. That's why I eventually used a shorter muffler and tucked it behind the radiator frame. That and cutting on the catalytic converter could present a warranty issue if not a federal crime if inspected by the wrong people. I know that sounds extreme, but I have been told not to touch the catalytic converter, because ANY modification to a factory installed emissions device is considered a federal crime in all 50 states. I'm not saying don't do but I don't think a dealer would.

 

[Fortsand]

Well, I am sure glad I did not run into that much trouble getting mine installed. When I first went to the local shop, he did some measuring and ordered the 15". I made it plain that I did not want anything forward of the connection behind the catalytic converter touched and they didn't as the pictures show. The day I went in to get it installed, they did have to think about it to get it on the rack. What they did was back it up on the rack, then put some lumber behind the front wheel for it to negotiate the rack. Once they had it on the rack, two guys worked on it and they knew what they were doing. I was actually there less than an hour. They measured, cut, and welded just like clockwork, it was no problem for them. <br /><br />
On another note, if a shorter muffler is used that will fit behind the fan housing, it will hit a suspension member. If you look above your present muffler you will see some linkage just above your muffler.<br />
<br />
There is just no room in that spot where the stock resonator is installed.

It appears that TBMS put in that spot what would fit, but it looks like at least they could have used a muffler instead of the resonator.

 

[Fortsand]

Here's a picture that shows just how close the muffler comes to the suspension member. So if the muffler is short enough to miss the<br />
fan housing, it still can't go up much because of this linkage.<br />
<br />
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<img src="http://i549.photobucket.com/albums/ii399/Fortsand/Stallion20Dec0825.jpg" border="0" alt="" />

 

[Papa Zook]

Joe- You're right on the tight fit. There is little extra room for a large, quite muffler. The one I use fits in the same spot but isn't as quite as yours.

Mattell- Let me clarify my last post. As far as the catalytic converter mod goes, shortening and re-welding the cat tail section to make the muffler fit probably does not constitute a modification that violates or is punishable under Federal Law. My legal adviser is a senior partner in the Cochran (if it dont fit), Cherry & Givens Law Firm and won the largest product liability settlement in Alabama's history so if he says dont touch it I dont.

 

[Mattel]

Take a look at this. It outlines EPA answers to the Catalytic Converter issue:<br />
<br />
<a href="http://www.epa.gov/otaq/regs/roadbike/420f03045.pdf" target="_blank">http://www.epa.gov/otaq/regs/roadbike/420f03045.pdf</a>

 

[Papa Zook]

Im looking at it from a Stallion Dealer and a Exhaust Manufacturer's point of view liability wise. I read the regs through and still didn't get much from it as far as specifics. Whats your take on it?

 

[John Luciano]

It sounds like you can do any modification you want to the motorcycle as long as , if it is tested , it is still getting the emission reading as it did before you modified it.

 

[Mattel]

I think that is what they are saying. You can mess with it, but don't change the results of the pollution control. I took off the rear one, but then I had them put it back on. You can shorten and lenghten the pipe all you want. I believe I am within the law, and I am much happyer that I am not creating any noise polition anymore. I am sure my standing in the Harley crowd just dropped.

 

[Road Runner]

Had a quieter muffler installed today. It is an oval, 14 in long. IMCO T904.<br />
We mounted it behind the 2nd catalatic converter. Is still in front of the rad. brace, not too low to ground either. Reattached the original dual exhaust tips.<br />
<br />
I dont know how to add photos yet, but will email pic to anyone that requests. <br />
<br />
Yeah, much quieter now. <img src="images/smilies/grin.gif" border="0" alt="" title="big grin" class="inlineimg" /><img src="images/smilies/smile.gif" border="0" alt="" title="Smile" class="inlineimg" />

 

[Mattel]

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<img src="images/misc/quote_icon.png" alt="Quote" /> Originally Posted by <strong>Road Runner</strong>
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<div class="message">Had a quieter muffler installed today. It is an oval, 14 in long. IMCO T904.<br />
We mounted it behind the 2nd catalatic converter. Is still in front of the rad. brace, not too low to ground either. Reattached the original dual exhaust tips.<br />
<br />
I don't know how to add photos yet, but will email pic to anyone that requests. <br />
<br />
Yeah, much quieter now. <img src="images/smilies/grin.gif" border="0" alt="" title="big grin" class="inlineimg" /><img src="images/smilies/smile.gif" border="0" alt="" title="Smile" class="inlineimg" /></div>

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</div>Road Runner,<br />
Just go to manage attachments and then click on the browse button and select the picture and then click on the upload button. Just make sure your picture is a low resolution. It is simple.

Give it a try, I would love to see how yours came out. The shop I used lost their shirt and welded everything! There was nothing I could do about it. I am stuck with it, but I am very happy with the sound. I would rather have a little higher clearance, but like I said, I am happy with the sound. This is one of the best modifications in my eyes for the Stallion. I would rather enjoy the sounds of the ride, not the ringing in my ears. You can tell I ain't no Harley rider!

 

[Road Runner]

Photos of muffler change.

 

[Nana]

Pictures look great, Road Runner!

 

[Road Runner]

Stallion Exhaust, more photos

Here are more photos of muffler change out. Had a local independent shop do the work. Ran the front tire up on 2 2x4, then a 2x4 between lift pads and frame to protect coolant pipes.

 

[Big Dog]

Road Runner, it looks like a very neat and clean job. I can only hope the sound level is lowered to what you wanted it. We can only hope that TMS is looking at solving this issue on future Stallions as well as a retro for the rest of us.:yes:

 

[Mattel]

Great pictures RR. Can you post one with your Stallion on the road so we can see the ground clearance on the muffler. How do you like the sound now?

 

[Road Runner]

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<img src="images/misc/quote_icon.png" alt="Quote" /> Originally Posted by <strong>Mattel</strong>
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<div class="message">Great pictures RR. Can you post one with your Stallion on the road so we can see the ground clearance on the muffler. How do you like the sound now?</div>

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</div>Mattell, Lowest point of muffler has 4 1/2 in. clearance from road. The twin exhaust extensions have 3/4 in. to bottom of plastic.<br />
I can post a photo later on. The sound is satisfactory now, much quieter.

 

[Mattel]

RR,<br />
That is prety good, I have 3 1/4" to the low point on the muffler. It rises to 4" at the side, as the muffler is slanted twords the rear below the bar.

 

[John Luciano]

That seems really close to the ground. I just measured my rear low points (on my Goldwing ). MUD FLAPS are 6" ( bottom of the flaps are worn from scraping at times ) Trail hitch sticks out the rear 6" from bumper and is 6" off the ground and I bang it often on steep drive-ways. My muffler tips are 10" never touched anything so far. I would think a speed bump would cause a bottoming out. I know what you are saying " I don't have a horse in this race " .. Just interested.
anyone have a before and after picture or a picture of one stock for comparison.

 

[Mattel]

It would seem that would be too low, but it is in line with the rear center of the wheels, so when I go over a bump or anything the whole bike rises up and I can clear anything, provided it is not sticking up and my wheels don't hit it.

Lets say a raccoon, it it was standing up or laying on the road and it did not go under my tire, it would have a permanent indentation in the shape of my muffler imprinted on its face (or worse) if it was above 3 1/4". I have rode about 1k miles and I don't have a mark on it yet (knock on wood).

 

[John Luciano]

From the pictures it was hard to tell it's relationship with the axle , but that makes sense.

 

[Road Runner]

In reference to asking TBMS to install quieter OEM muffler, I spoke to Jeff Vey at the Wing Ding rally last week. He says that some want it quieter and some want louder, and he cant please everyone. So, seems like no change will be forthcoming. BTW, the bare Stallion with no plastic attached, on display, was very interesting. Now I know where most things are located. Took lots of photos to help my old memory too.

 

[Mattel]

Thanks for using this thread RR. If the others read all the info on this thread they may not have removed their CC, and left themselves open to federal law violations, and it will also make it harder to sell their bike in the future. CC's are expensive...

I took some high res pictures of the naked stallion too. I need to post them in my photo album if I did not do that already. That is great info when doing repairs!

The info they were providing was very helpful and appreciated, but it is misleading to others who are not aware we have two threads with the same info, they may miss critical info like not removing the cc's.:yes: