Harley-Davidson Sportster mufflers can be easily adapted to fit most GoldWings. The chrome quality on H-D parts is absolutely stunning. Most new owners of Harleys will immediately remove the stock mufflers and put on a set of loud'n'obnoxious
ones. That means that there is a ready supply of brand new pipes for us to scavenge. Ask your Harley buddy about that 24"x10"x4" box on his garage shelf. It's probably the stock mufflers off his bike. Or, check with the local H-D dealer and watch Craigslist and eBay.
Shown below is a set of 2003 Sportster mufflers installed on my bike. (NOTE:
'03 was the last year for non-baffled Sporty mufflers.)
The view that most people see of my mufflers.
Here's a shot of an unmounted set of '02 Sportster mufflers.
The two mufflers in a pair are identical except that the one you'll use on the right side has a larger hole thru its mounting tab. The one for the left side will have the stamped-in lettering on the top, outside of the mount.
There will be a dimple at the rear, on the top of the left one.
Mounting the Sportys on a GL1100
- Remove the old mufflers and headers (be sure to get the "squash" washers out and replace them with new ones).
- Carefully cut the chrome covers off the headers. These will be remounted so don't mess them up.
- Cut and grind the header exits to get to good metal.
- Get two 4" x 1-3/4"O.D. pieces of muffler pipe at Advance Auto, AutoZone, Pepboys, etc.
- Temporarily remount the headers (without squashies), slip the bolt thru the new muffler and onto the stock mount.
- Line it all up and trim the 4" pipes to the correct angle and length.
- Tack weld the now-modified 4" pipes to the headers.
- Move the headers to the bench and put a good weld around the joint.
- Tack the chrome covers back onto the headers.
- Put in the new squash washers, install headers and torque down bolts.
- Put H-D muffler clamps (or radiator clamps) over the header ends.
- Slip the mufflers onto the headers. Tighten frame connection then muffler clamps.
- Go for a ride!
With the mufflers mounted directly to the stock mounts, I thought that the left one was too far out and too high. The centerstand also struck it. So I made a bracket from a 1" piece of strap steel. It's now about 1/2" too low at the end (see the rear pic above) and still maybe an inch too far out. I also added a rubber-baby-buggy-bumper to catch the centerstand. These pics were taken from the rear.
Initially I used radiator clamps at the junction but they blued quickly and I ended up buying a set of '02 Sportster clamps from the H-D dealer. $8 each. Again, great chrome!
They sound great, rumbly but not too loud.
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