HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim ?

Hi ! I am relacing my stock XJ650 mufflers with the Harley Davidson Sportster mufflers and was wanting to know if anyone who has done this could enlighten me on what they had to do to fit them on the bike ? A picture of the finished results would be great ! Did you have to weld them on or clamp them ? Like I said it before pictures of the sportster exhaust on a XJ 650 would be Fantastic ! THANKS DON

 

I put Screamin Eagles on mine.
Here's what I did,but you my find a better way.

The slip over ends were too big for the collector outlets.
But they did fit nicely over the ends of the stock pipes.
So I cut the ends off the stock muff's and JBWelded then into
the new ends.
They slipped right back on to the collector.

NOTE; you will see that the clamp has to be drilled off or
just repaced with a new one.
One end of my new mufflers had been buggered up a bit
and the fit was not perfect. I still have a small amount of
wiggle on one side but only because I haven't used a heavy enough
clamp to sqweeze the pipe.
So good luck!
Check my gallery and you will see them there.

 

Oh yeah, I almost forgot.
My center stand used the old pipes as a rest.
You will have to make a bracket either on the new pipe
or...and this is what I did, make a new bracket that runs
from the old frame mount,around the back side and under
the new muffler.
I did it this way after putting it on like the stock version.
I didn't like the way it would bounce against the new muffler
and figured it was going to knock it loose eventualy.

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

Parts ! Thanks for replying and your setup looks nice ! I would still appreciate anybody that has replaced the stock mufflers with the sportster mufflers to chime in because I think there is others that might consider this swap. THANKS TO EVRYONE ! DON

 

this is a common swap, I did it on my 700, I had to use adapters, and I used automotive clamps (oops) sounds REALLY good, a throaty sound, and I like the looks

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

I've had Screamin' Eagle mufflers on mine and I found them a bit too loud for my tastes. Then I bought a pair of stock Sporster mufflers at a swap meet and put them on. They slid right onto the header pipes, no problem. I had to make short hanger brackets tothe muffler studs, which wasn't an issue. They sound a bit lower rumblethan the stock mufflers, which is a plus (never liked wimpy stock muffler sound) Mines an XJ 750 Seca.

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

PainterD -- Could you post a picture of the mufflers on your bike ? I would appreciate it if you would. Did you have to rejet the carbueters ? THANKS FOR YOUR INPUT ------ DON

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

Yes, I can post a photo for you Illinoisxj650, but I still need to figure out just how to do it on this new computer we just bought. I will go out in the shop today and take a photo of the mufflers, so give me some time to figure out how to get them here.
No, you willnot need to rejet with the Harley mufflers (stock, not gutted out) you may want to adjust the air mixture screws however. I don't have one, but a color-tune setup is highly recommended by many around these parts.

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

I hope this works. Here's my Harley Mufflers (photo taken last winter)
Not the best pictures, but you get the idea.

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

PainterD : I very much appreciate you going to the trouble of posting a picture and they look great ! I do have a 14mm color tune that I just purchased. ! THANKS AGAIN AND TAKE CARE---- DON !

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

What year sportster mufflers fit? Anything specific or all of them? I found a cheap pair of brand new ones on Craigslist for cheap...

 

bump...

I'd like to know the answer to that too.

 

I believe Pre-2003 or you can get universal mufflers(Sportster like) from JCWhitney for pretty cheap. They also have reducers and clamps if you need them.

 

The new ones I believe have some ports or something you do not want, so get the older ones, iirc it is pre2003 (?) but am not sure, search old threads to find... Good luck!

 

So just changing muffler won't require carb re-jetting will it? I've read doing a sportster swap won't require it... how bout those JC whitney mufflers?

 

Would this work?

http://www.jcwhitney.com/patriot-univer ... 2y1982u0j3

 

I think those are tips, so they would not have muffling, but you would be using straight pipes.

 

Well with no muffling and just straight pipes, would a carb re-jet need to be done?

I wouldn't mind going to straight pipes, I'll probably do that once I learn how to make this thing a bobber

 

From what I have read, the straight pipes would likely require jetting since they are so unrestricted.

 

Strat put exhaust tips on his 700 (no muffler) without having to re-jet.
If your just replacing mufflers with mufflers, shouldn't require a re-jet.
These:
http://www.jcwhitney.com/emgo-universal ... d=c14681j1

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

Just put these on tonight and took if for a quick spin, they sound really good compared to stock mufflers that the PO drilled out (and left part of a drill bit inside to boot!) So im not coming from what a normal stock exhaust sounds like, but I dig the sound, its more mellow that what im used to, and a little deeper too.

http://www.ebay.com/itm/07-r6-GP-Style- ... 51&vxp=mtr


I dont know how to insert a link properly, sorry.

 

Anyone got video or sound clips of the aftermarket setup? I want to see what this new deep rumble might sound like.

 

random, did that go on pretty easily? Do you have a pic of what the bike looks like with it on?

 

It took a trip to the auto parts store for a reducer and a muffler clamp. I'm using that temporarily until I can get to the shop on a day off work. I had to cut slits in the nreducer so it would get even smaller when I clamped it down and the result was an oval shape between the reducer and collector, so I wouldn't run it permanently as there is a small gap.

When I was looking for the link to the exhaust on fleabay last night I saw that they offer a "double baffle" and kinda wished I had done that.

I will post a pic later this evening.

 

Sweet, looking forward to seeing that set up. No need to re-jet?

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

]Video of exhaust[/url]

I hope i added this correctly....Im having an interesting time adding photos and video...

]I hope this works...[/url]

]I hope this works too...[/url]


Keep in mind, this was just set up in my garage...its not permanent. I still need to get to the shop to make it a little more complete.

 

I like it man, it's got a nice rumble too! So no re-jetting necessary? I have 2 mufflers, so I'm looking for an inexpensive solution that also won't require re-jetting.

How did you get that single seat on there? That's another thing I really need to do. I absolutely hate my monstrosity of a seat.

 

Re: HD Sportster Muffler Replacement for Yamaha XJ 650 Maxim

+1 on Kleraudio. Looks and sounds great :wink:

 

I don't think I need to rejet. It seems to be running as usual.

The solo seat is temporary, but I just took a piece of metal and drilled a couple holes in it, then heated it up with a propane torch and bent it with a hammer. I'm in the process of making a seat but it's not coming out too great. I'm thinking of getting a seat from a salvage yard if I can find one and have a day off work to go.

 

I tried the Sportster pipes route but my bike started running on 2 cylinders leaking oil and replacement parts were way over priced. I did, however, feel superior to all other bikes on the road.......

 

:lol: :lol:

 

I see what you did there 8O