Biltwell Mini Mufflers slip fit over the open ends on 1-3/4-inch O.D. custom pipes to change the look and sound of the motorcycle exhaust system. A perforated steel baffle tube with fiberglass wrapping inside the Mini Muffler can be removed to change the exhaust note. Biltwell Mini Mufflers come in different 3 styles Javelin, Cannon and Stinger, with two color options, chrome and black. For this project we decided to install black Javelin Mini Mufflers onto our black Lowbrow Customs Shotgun Pipes which compliment each other really well.
Tools needed for the job
one- 1/2 inch socket
two - 1/2 inch wrenches
a hacksaw, pipe cutter, or angle grinder
one - 7/16 inch wrench
one - 1/4 inch allen socket
assorted files of your choosing
Installing Biltwell Mini Mufflers onto Lowbrow Customs Shotgun Pipes
Step 1. Locate the middle of the mounting tab on the back of the muffler. Line up the center of the tab on the muffler with the rear bracket mounting holes. Mark the Shotgun Pipe where the cut will be made, make sure to leave enough excess pipe to insert into the muffler flange.
Step 2. Unplug O2 censors.
Step 3. Using both 1/2 inch wrenches remove both nuts and bolts from the mounting tabs at the rear bracket.
Step 4. Remove top pipe from the front cylinder head using a 1/2 inch socket.
Step 5. Use a pipe cutter, angle grinder, or hacksaw to cut the shotgun pipe along the line you marked. If using a hacksaw or angle grinder, it is very important to keep the cut as straight as possible.
Step 6. File off any jagged edges along the cut on the inside and out of the Shotgun Pipe.
Step 7. Using a 7/16 inch wrench, make sure the baffles are tight on each muffler.
Step 8. You will need two exhaust clamps to secure your mufflers to the pipes, (we used Biltwell’s 1-3/4” Duo Muffler Clamps in black)
Step 9. Reinstall Shotgun Pipe to front head loosely.
Step 10. Loosen clamp to allow it to be slipped over the muffler. Then slide muffler on to head pipe.
Step 11. We chose to stagger the mufflers a little to compensate for the larger diameter of the Duo Muffler Clamps. Locate the middle of the mounting tab on the back of the muffler. Line up the left of the tab on the muffler with the rear bracket mounting holes. Mark the Shotgun Pipe where the cut will be made, make sure to leave enough excess pipe to insert into the muffler flange.
Step 12. Remove top Shotgun Pipe, remove bottom Shotgun Pipe, and repeat steps 5-8 on bottom Shotgun Pipe.
Step 13. Reinstall Shotgun Pipe into the rear cylinder head.
Step 14. Secure clamp to muffler loosely and fit over Shotgun Pipe.
Step 15. Reinstall front Shotgun Pipe with muffler.
Step 16. Evenly tighten both Shotgun Pipes at the heads and rear mounting tabs. Adjust pipes till your lines look straight. Make sure to tighten Duo Muffler Clamps.
Step 17. Plug back in your 02 sensors and go for a ride.
Step 18. Note: When attaching mufflers to rear bracket, you may need to add a washer in-between the tab on the muffler and the rear mounting bracket to be sure that the bolt will not come into contact with the muffler when tightened.