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Upgrade The BullDog | Big Dog Exhaust Pipe Swap

Tech

By Ernie Lopez, Photography by Ernie Lopez
Big Dog Exhaust Pipe Swap 1

It's time to get a little bit more from our Big Dog BullDog Bagger. We have had the bike for a few months now. The ride time on the bike has been fun with all the power and comfort but we were told that Big Dog offers a set of slip-on mufflers that take the exhaust from a 2-into-1 canister to a set of stacked duals. It is a quick and easy upgrade that will add to the bike's look and performance. So we ordered a set and headed over to Horn Cycle Works in Pomona, California, our local Big Dog dealer, and had the guys do the install and a few runs on the dyno.

  • 01. Here is the BullDog with the stock 2-into-1-muffler setup. The power and sound was decent but we wanted a deeper sound and hopefully extra horsepower.
    01. Here is the BullDog with the stock 2-into-1-muffler setup. The power and sound was de
  • 02. The first thing shop tech Nolan did was drill a small hole into the stock muffler canister so he could get an accurate air/fuel reading on the dyno.
    02. The first thing shop tech Nolan did was drill a small hole into the stock muffler can
  • 03. Next, the bike was given a run on the dyno and the numbers for the 111ci engine were: 94.1 hp and 91.4 lb-ft of torque. The air/fuel was good throughout the run at about 13.5 to 1.
    03. Next, the bike was given a run on the dyno and the numbers for the 111ci engine were:
  • 04. Once the bike had time to cool down, Nolan got started by removing the side covers to access the battery box and electrical terminal. To get to the lower inside mounting bolts on the muffler, he disconnected the wires for the rear lights in the saddlebag. He then removed the four mounting screws from the inside of the saddlebag and placed the bag in a safe place to protect the paint from getting scratched.
    04. Once the bike had time to cool down, Nolan got started by removing the side covers to
  • 05. First, the setscrew was removed from the bottom of the billet end cap, then removed from the muffler.
    05. First, the setscrew was removed from the bottom of the billet end cap, then removed f
  • 06. The one-piece chrome muffler cover was then removed by sliding it off.
    06. The one-piece chrome muffler cover was then removed by sliding it off.
  • 07. This is the stock muffler; you can see that it's a one-piece canister.
    07. This is the stock muffler; you can see that it's a one-piece canister.
  • 08. Here are the new slip-on mufflers.
  • 09. Looking at the mounting brace for the mufflers, you can see (arrow) that it has a rubber-mounted center isolator. This helps absorb the vibrations from the motor and with the motor being rubber-mounted allows both to move together with less stress on any mounting points.
    09. Looking at the mounting brace for the mufflers, you can see (arrow) that it has a rub
By Ernie Lopez
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