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Big Dog Pipe Upgrade

More Bark For Your Bike

By Ernie Lopez
  • Big Dog Pipe Upgrade Big Radius Pipes
    The Big Radius pipes feature 2-1/2-inch full-coverage heat shields, scalloped end tips, a mounting bracket, new intake-manifold gaskets, exhaust gaskets, and flanges and caps. After the stock two-into-one pipe was cooled down, Randy removed the old pipes.
    Big Dog Pipe Upgrade Big Radius Pipes
    The Big Radius pipes feature 2-1/2-inch full-coverage heat shields, scalloped end tips, a

You and your motorcycle. What can you do about the missing sound and power from the bike? You know-from all you were told when you bought the bike, there should be a lot of power still hidden in that big-inch motor somewhere, but where? If you're like most riders, style, performance, and sound are what you're looking for when it comes to your bike.

So what happened to all that power? A quick two-word explanation would be "governmental regulations." The motorcycle industry has to conform to many seemingly never-ending new regulations. In theory, these regulations should be a good thing for long-term health issues, but they make our bikes run far below their rated capacity.

This became apparent when we dyno'd an '06 Big Dog Mastiff and only recorded 97 horsepower-from a 117-inch motor. We called the factory to find out what options were available, and we were directed to the Big Radius exhaust system. While the pipes alone would not solve all of our missing power and sound issues, they would give us a deep, throaty sound and add to the stock horsepower numbers.

The Big Radius two-into-two performance pipes have style written all over them. The system includes the pipes with heat shields and all the necessary mounting hardware. The MSRP for this set is $649 (recommended jet kit sold separately.) This is not a street-legal kit, since after we install the new pipes the bike will not meet the EPA's noise regulations and noise emissions standards, but we still like the look of the pipe.

We stopped at Lifestyle Cycles (a Big Dog dealer) in Anaheim, CA, to install and get a few dyno runs in. Before we knew it, Sparky and Randy had the bike up on the dyno, and it was ready to go. They ran the bike on the dyno with the stock pipe to get some base numbers, which turned out to be 107 lb-ft of torque and 97 hp.

  • Big Dog Pipe Upgrade Bracket Mounting Bolts
    Next, a small amount of threadlocker was applied to the bracket mounting bolts. Then he bolted the new mounting bracket onto the frame.
    Big Dog Pipe Upgrade Bracket Mounting Bolts
    Next, a small amount of threadlocker was applied to the bracket mounting bolts. Then he bo
  • Big Dog Pipe Upgrade Remove Old Gasket
    Then he removed the old exhaust gaskets and installed new, thicker gaskets.
  • Big Dog Pipe Upgrade Exhaust Flanges
    In the bag of hardware there was a new set of exhaust flanges and retainer clips. The head flange was installed first, followed by the retainer clip.
    Big Dog Pipe Upgrade Exhaust Flanges
    In the bag of hardware there was a new set of exhaust flanges and retainer clips. The head
  • Big Dog Pipe Upgrade Mounting Bracket
    Next, the bolt insert was placed in the exhaust-pipe mounting bracket. Randy loosely bolted the pipe to the head until he got the rear of the pipe bolted to the bracket.
    Big Dog Pipe Upgrade Mounting Bracket
    Next, the bolt insert was placed in the exhaust-pipe mounting bracket. Randy loosely bolte
  • Big Dog Pipe Upgrade Tighten Head Bolts
    After everything was lined up, he tightened up the head bolts.
  • Big Dog Pipe Upgrade Heat Shield Installation
    The heat shield was installed next. The clamps were placed in the keepers, and then the shield was placed over the pipe. Finally, the claps were tightened.
    Big Dog Pipe Upgrade Heat Shield Installation
    The heat shield was installed next. The clamps were placed in the keepers, and then the sh
By Ernie Lopez
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