There are two mods on this page, the JC Whitney one & a later Harley Dyna one added after the first.
Be advised that the 1985 through 1996 EN500 (NOT the EN500 LTD, they had BOTH models in 1996) has a problem with having different mufflers, and only a 1 3/8" diameter pipe after the crossover, where the LTD series have a 1 1/2" pipe. A Yahoo EN500 group member pounted this out. The JC Whitney reducing set shown later (CBM063889 @ $4.99 per set) goes down to that size using all three reducers, and should take care of this problem, where I only used two on the 2002 model.
JC Whitney pipes Mod (and general part for ANY later muffler changeout)
Here is an exhaust mod that I tried but was a little too loud!
Two of my neighbors who are HARLEY riders complained about the noise!!! Methods would be the same with different pipes. I will try several before I am done.
First remove the standard muffler by loosening the bolt at the front and removing the two Allen head screws to the frame.
Now we see the 1.5” header pipe from the cylinders, just behind the pressure equalizing crossover pipe.
Now here is a view of the JC Whitney muffler (P/N: CBM017333 @ $27.44 each) as it comes.
The long chrome hanger isn’t used. We will use a pair of Tucker SO-3790 straps (we will bend them a little more than they come later)
Here one is shown installed on the muffler and a sharper bend has been made at each end.
This 1.75” by 1.5” reducer comes with the muffler.
There are two ways to mount the system. One is to just have a local muffler shop take an 8” piece of 1.5” pipe and expand it so it fits over the header end, and fit into the reducer, which then goes directly into the muffler. A real simple and cheap method, and fine if you put a heat shield in front of it so you don’t see the ugly pipe. (No chrome! Gadzooks!) With this method, you are mostly done already!! It does take a crimp type clamp to hold it on (quite loose) and that could hurt the header pipe, so be careful if you use this method!
OR you can get a three part reducer set from JC Whitney (P/N: CBM063889 @ $4.99 per set)
I chose to get fancy and bought some chromed 1.75” OD (outside diameter) automotive “pencil tips” that you put over car pipes to give the chromed illusions. I cut off the rolled and flared ends (you will understand when you see them. I didn’t take any photos before I cut them) or just order 1.75” stainless pipe and have it expanded as before. NOT chromed pipe as expanding it cracks the chrome plating off and looks like caca. Either way you wind up with another 8” or so length of pipe that you can put the smaller size reducer into. The stainless polishes real nice or the chrome blends right in. The reducer has a gap so I used high temperature Permatex copper filled RTV (from any car store or hardware store) to fill the gap and reduce leakage. Some leakage won’t hurt the bike a bit as all muffler systems leak and it is far enough from the header connections to the engine block that it won't cause overheating.
Now with the pipe and reducer on the 1.5” header end, it looks real good even without a heat shield (which is still a good idea. It does get very hot)
When it is pounded up to the header end snugly (with a rubber or leather mallet so you don’t mar the thin chrome, it looks like it were made for the system.
Now the muffler fits right over the pencil tips, which have an OD (outside diameter) of 1.75”, which is what most mufflers are at ID (inside diameter). The EN500 originals or just about all Harley’s are.
Bolt down the muffler to the last support holes (takes some GENTLE bending of the whole assembly to align screw with hole)
Now use any good heavy duty 1.75” clamp to hold the muffler onto the pipe. I bought mine from Heavy Duty Cycles in Lompoc. A little more than mail order but buying local get help local too!
You want to turn the bolts sort of inward so they don’t protrude as much or catch on stuff. I also use hex head bolts more than any other as they are smaller, look better, and don't get rounded off from impact or wrench use.
You don’t need to fasten the pipes to the frame or anything else, as the clamp to the new header extension and the rear screw hold enough tension to keep them on snug. After several hundred rough road miles, I found no movement whatsoever. In the following pictures, you can see what they look like from the side and back. Quite an improvement from the “bugles” or megaphones style look.
NOW, they ARE NOT quiet! I wasn’t joking about the HD guys complaining. They are louder than two Road Kings running TOGETHER! They also sound like a Big Harley breathing helium! You know, LOUD but hi pitched! That pitch is, unfortunately, a factor of the engine design (read about V-Twins vs. Parallel twins and angles of rotations and valve cycles for an in depth understanding. LOTs of good posts on www.Kawasaki.org forum about that, most of them very accurate!
I have since tried them with some partially baffled Custom Chrome mufflers built for the ’87 Harley XL I bought on eBay. They are not as loud, mount almost the same (just use forward screw hole on frame) but are still loud enough some Goldwing friends say they can hardly hear when someone talks on their radio and I am within 200 YARDS, in front or back!!!
I am going to find some HD pipes that are fully baffled (all flow is through a baffled network rather than just some and a straight through hole in the middle. I don’t have the numbers yet, but I found and old set that were fairly loud, not TOO bad, and a LOT mellower (lower) sounding. I again want to praise Ray Leslie and Ralph at Heavy Duty Cycles in Lompoc for all their help through this. For guys that snarl if you ask for a metric bolt, they are great. (I think they wash their hands after touching my Kawi though)
The Harley Davidson Pipes Are On!!
Sound file link on last page!
Finally! I have a set of pipes that sounds great! These are HD Dyna mufflers that are fully baffled (like a lot of riders I know) with no straight through component. While the EX500 engine will always have a higher pitch because of the engine configuration, these pipes give it a much louder, throatier sound WITHOUT complaints from my HD owning friends and neighbors!! The first ones I have had a lot of feedback on, telling that most people like them, but like I have mentioned, they sounded a bit like a Grizzly sized Harley breathing helium! These Dyna pipes are sweet. Sounds like a real bike, but not rattling any window panes or eardrums. I did set in amongst a pack of HD's the other day though, and I finally got to hear mine while there!!
Now, we install them just about the same way we did the others with a few simple changes. The HD mufflers use a mounting system where the mufflers bolt to a frame, that sort of bolts up to the bike. The Dyna part numbers are: 65747-94. At least one person emailed me that they got a great set for $35! I paid a little more, but these are almost new. Still cheap, as they cost HD drivers around $300+ EACH to replace!! And that's OEM equipment! NOW, do you remember one of the reasons we ride Kawi's???
Here is a picture of the muffler (the same model is used for both sides. The way we will mount them, the bolts all go inward! You can get a slash set, but make sure that the slash side will point OUT when on YOUR bike, not on the original!! That means they have to be mirror images of each other.
Notice the slot with the hole? That is where we will use a "carriage" type bolt to mount the bracket. The round head (shown in next picture) goes down into the hole midway along the slot, and the square neck of the bolt, just below the head, stops it from turning as you tighten or loosen the nut. I advise you to wait and get the mufflers first and THEN get the bolts. I got some from the HD dealer but they were too long and I hate cutting plated bolts so that rust has a better chance! Plus, the ones I have were a little loose when used with a 1/4" bolt, and too tight for a 5/16". I finally used a 5/16" set and opened the slot a couple of strokes of a bastard file. (No, I am not mad at the file, that's what their called!) Here is a better view of the whole muffler. See the clean inside?
And below are the bolts, washers and nut I used to fasten them on. The chrome strap was just a generic I picked up at a HD dealer, but just about every bike parts and accessories catalog has them. I used one about 9" long and had to drill the hole in one end, but with that long slot to adjust with for different lengths, it could be inches longer or shorter. Whatever you come up with should work fine. The red bolt is an 8mm metric that fits into the holes used for mounting the original mufflers. You know me and my "keep it original" ways by now!
Here is what the strap looks like with the carraige bolt ready to insert into the hole, and slide along the slot to the best adjustment point. Make sure and snug it up so ther isn't too much room more than the width of the strap, BEFORE putting it in the slot, or it will be hard to hold the square neck part in the slot to keep the bolt from turning when you tighten it !
Here, I have snugged it into place but not tightened the bolt yet. I want to bolt the other end of the strap to the frame first, to make sure they are positioned where I want them, and then I will tighten the carriage bolt down later.
No matter which one you turn what way, one will show no markings and the other shows the label stamped in that states it belings on a Harley and is illegal to install on anything else! So is EVERY AFTER MARKET MUFFLER!! Who cares? It sounds great and about a fourth of the rumble, rattle and roll of HD's! (with the same muffler!)
Here we have bolted the bracket to the back frame mount, but you can use either one depending on the angle you want, and the length of bracket stock you use. Just slide the carriage bolt along the slot until you like it, and cinch 'er down!
Please excuse all the dirt you see. The Wannabeabigbike and me ride a lot, and only I bathe frequently! (that's my story and I'm stickin to it!) I modify her to death, ride her close to mine sometimes, but polishing and stuff ain't for me untill I just CAN'T do anything else. That's why I love chrome. A little sunshine and everyone is so blinded they can't see the dirt!
This picture shows the muffler end of the clamp tightened down and ready to finish.
I put the clamps (Heavy duty, from almost any catalog) on with the ears mounted up this time as I just installed the Scootworks lowering kit (Wow! Does that make a difference in the way it sits! Love it! Just doesn't go on quite as easy as they say! A mod story on that to come, OTHER than the sad tale at the home page start! One thing about mods, you have to REMEMBER you did them!!) These ears will be twisted towards the inside where they are hard to see, and then covered with some generic (again) chrome heat sheilds. I used two heat shields from two different companies, because the Harley dealer had one each and made me a bocou deal on them. After taking them out of the two competing company's packaging (OURS is better!!), I couldn't tell them apart!! Kind of like the generic air in cans used for cleaning dust off computers! (A company called BlowOff actually makes about 90% of them and just labels them for different companies. Sometimes with a different can or color top, but the same product just the same!) I used the same adapters I made in the first part of this mod, for the JC Whitney pipes.
Looks ugly so far, huh? Well, we'll fix 'er!!
Here is what we have when it has those competing heat shields in place. Not bad, even if I do say so myself! And of course, I do, as I am writing this and get to it I want to. I hadn't twisted the mounting clamp ears back out of sight yet because I am working on some stuff (more mods!) underneath, and didn't want to wait to take the pictures.
OK, we done. Go and sin no more!! Just ride, cowboy, ride!!!
AND, hear yourself do so for a change!!!!
Here is a link to the Photobucket sound file. It actually sounds a little louder and a lot deeper than what the camera captured, but it's close!