Exhaust options for 2001 Big Dog Boxer?

[johnwink]

Hi all,

So I finally have my 2001 Big Dog Boxer and... It's a little too loud. It currently has a set of headers running into a 3" pipe with no baffles. I'd rather be much, MUCH closer to stock.

Does anyone know what was the OEM exhaust on these bikes and where to find one? Or can anyone confirm that OEM Harley Dyna pipes from 1995-2004 will fit?

Thanks!

John

 

[Mr. Wright]

The two into one that he has linked on this thread are really nice, and inexpensive too.\
http://www.bigdogbiker.com/forums/exhaust/72112-softail-exhaust.html

 

[FrankBDPS]

John, contact bigdogpartsking they may have the original Kerker 2 into ones. If you search my post I have pics of the one I put on my bike.

 

[johnwink]

The two into one that he has linked on this thread are really nice, and inexpensive too.\
http://www.bigdogbiker.com/forums/exhaust/72112-softail-exhaust.html

Looks like these were a straight bolt-on to your '03 Chopper, any idea if the fitment is the same for the '01 Boxer? what does your mounting bracket look like?

Thanks!

 

[johnwink]

John, contact bigdogpartsking they may have the original Kerker 2 into ones. If you search my post I have pics of the one I put on my bike.

Thanks, I'll look into it!

 

[johnwink]

The two into one that he has linked on this thread are really nice, and inexpensive too.\
http://www.bigdogbiker.com/forums/exhaust/72112-softail-exhaust.html

Looking at these, they fit a Softail. There's also a version for the Dyna.

I'm not clear on whether we're supposed to buy Softail or Dyna exhausts for the 2001 Boxer... I've seen both mentioned in these forums and I don't know what is the right answer. I tend to believe it's the Softail since my current Hooker FourBidden exhaust was apparently only made for Softails, but I'm somewhat loathe to lay down $350 before I know if the pipes'll fit.

Anyone know for sure whether a 2001 Boxer needs a Softail or Dyna exhaust?

Thanks a million!

 

[Mr. Wright]

It's the same as a soft tail Harley. I would imagine the Boxer would be the same. I'll take a picture when I'm home at noon and post it for you.

 

[johnwink]

The two into one that he has linked on this thread are really nice, and inexpensive too.\
http://www.bigdogbiker.com/forums/exhaust/72112-softail-exhaust.html

It's the same as a soft tail Harley. I would imagine the Boxer would be the same. I'll take a picture when I'm home at noon and post it for you.

That'd be really helpful, thanks! In particular it's the bracket to the bike that I'm wondering about.

Amazon has these for $350 with free shipping, $5 more than on eBay but their returns policy is fantastic. So if it looks good I'll just have to go order me some.

thanks again for the help on this, I owe you one.

 

[gabe]

A cheaper option maybe is to get some baffles for your current exhaust. I know big city thunder has a "quiet baffle" I don't know if this would work with your pipes or not but might be worth looking into.

 

[johnwink]

A cheaper option maybe is to get some baffles for your current exhaust. I know big city thunder has a "quiet baffle" I don't know if this would work with your pipes or not but might be worth looking into.

I looked into this, unfortunately the pipe is so danged short I don't have any options. I did find a 3" wide, 8" long baffle and that's the closest I got, but my pipe is 4" wide and I have less than 8" in length to work with.

I was considering replacing the tail section of the pipe with something like this (12" or 18" version) to give myself some extra length to install home-made baffles:

Dynaflex 25p 40012CP 4" OD x 12" Long Chrome Curved Exhaust Stack or Tail Pipe | eBay

But the guy couldn't tell me whether it would slip on to the 3-7/8" lip on my current headers. At the price I'm thinking of just ordering this anyway and giving it a shot (it's $33).

It's all good. I knew I was signing up for this when I bought a Big Dog sight unseen over the internet.

 

[Srodden]

You'll get more horsepower with some type of baffle and a little longer of an exhaust

 

[johnwink]

You'll get more horsepower with some type of baffle and a little longer of an exhaust

Thanks. I'm kinda torn between building my own (and as you say, making it longer with some good baffle) or buying off the shelf, assuming the ones I'm looking at will fit. Tending towards off the shelf at this point.

 

[Mr. Wright]

Sorry I got side tracked at noon. Hope these are helpful.
The first pic, is from the rear, looking forward. the bracket is part of the exhaust, and bolt straight to the frame.





Looking down.




And of course, from the side

 

[johnwink]

Thanks! This is totally different from the 2001 Boxer, but I'm pretty sure can be addressed with a custom bracket. Does your '03 have the 107" motor?

 

[Mr. Wright]

Yes, it the 107. I had a little problem installing them, because the pipe is bigger. Here's my original thread on that, and what I did to fix it.
http://www.bigdogbiker.com/forums/exhaust/56689-exhaust-question.html

 

[johnwink]

Yes, it the 107. I had a little problem installing them, because the pipe is bigger. Here's my original thread on that, and what I did to fix it.
http://www.bigdogbiker.com/forums/exhaust/56689-exhaust-question.html

I finally got my Big Dog service manual on CD and it all makes sense now.

Your Chopper is a solid-mount whereas the Boxer is a rubber-mounted engine. That's why your exhaust bracket is on the frame whereas mine is bolted to the transmission.

The manual I have shows a cross-reference list of Big Dog models to Harley models for exhaust fitment. The rigid mount bikes do indeed map to the Softail but the rubber-mount bikes map either to the FLT (Vintage) or FXR (ProSport, ProGlide, AeroSport).

Unfortunately the Boxer isn't listed, but since it's rubber mount with forward foot pegs I'll assume FXR at this point. FXR exhausts are pretty rare, so I'm thinking I'll need to get a Dyna exhaust and fab a bracket.

And if I'm wrong I'm out $350.

 

[FrankBDPS]

John,The label on my super traps stated they were for a prosport,husky or a boxer. If I remember correctly the reason my vance and Hines big shots did not fit correctly were that they were for a harley and not for a big inch S&S. Something about the exhaust port angles were slightly different.

 

[johnwink]

John,The label on my super traps stated they were for a prosport,husky or a boxer. If I remember correctly the reason my vance and Hines big shots did not fit correctly were that they were for a harley and not for a big inch S&S. Something about the exhaust port angles were slightly different.

Aaaaand... If I'd listen to you smart people instead of going off half-cocked I'd have saved myself a bunch of trouble (and an unfortunate pool of blood in the shop, but that's another story).

I got the Patriot exhaust in and indeed the exhaust valve angle was different. I'm surprised, I would have thought that they'd be the same since the S&S motors seem to be a common upgrade for Harleys.

So now I'm wondering how I know the valve angle for a given exhaust system. Per suggestions here I have a line on a set of original Kerkers from a member, but I'd like to explore other more exciting options and I frankly don't know what will fit anymore and what won't.

Part of the problem is in search engines... If I search on eBay for +"S&S" it gives me "S&S", "SS" and "S/S" so every sport bike stainless steel exhaust shows in the results. Very frustrating.

So I guess I'm asking two questions to the wise ones here...

1. How do I know if a given exhaust will fit my S&S 107" mill?
2. Are there any exciting alternatives to stock for a 2001 Boxer?

Thanks again for the continued advice. Again, I should have listened sooner as I would have saved myself a ton of grief!

EDIT: Still interested in the answers to these questions just for my own learning but it looks like bigdogpartsking can hook me up with a stock exhaust, so think that's the way to go. Thanks!

 

[FrankBDPS]

I don't regret putting the stock exhaust back on my prosport. They fit correctly,look good and sound great.

I think the difference in the motors has to do also with the overall height of the motor since it has a longer stroke.

Good luck

 

[johnwink]

I don't regret putting the stock exhaust back on my prosport. They fit correctly,look good and sound great.

I think the difference in the motors has to do also with the overall height of the motor since it has a longer stroke.

Good luck

I think it's the right answer too. I'm just confirming with bigdogpartsking that it is indeed the right exhaust for the 2001 Boxer. He's got one on eBay for a 2004 Chopper, but I don't think it's the same. After today's debacle I don't want to go through another mismatch!