This is more like what I did on it one day, then the next, then the next, and yet another day. I'll throw a summary/lessons learned in the Intake/Exhaust thread, but figured I would chronicle some of my experiences (and stupidity) here since it still fits with the top of the thread:
Fullsac Install - Day 1 (Monday)
- Removed exhaust system from the bike (2 hours) - A little slow, but I was trying to be careful. Took pictures of clamp positions in hopes that it would help with re-assembling.
- Installed and updated MasterTune software (30 minutes)
- Install additional chrome pieces to engine (4 hours) - I love a fully-chromed out engine, and I wish Harley would make more parts/covers for the 110 because trying to wrestle with Kuryakyn parts flat out sucks
Fullsac Install - Day 2 (Tuesday)
- Start installation of new header pipe (1 hour) - Realize that there are no mounting flanges on the new header pipe. Call Fullsac and leave a message. If I would have just spent the 2 minutes removing the C-Clips, I might have tried to slide the existing flanges off the pipe and saw that they would come straight off. I come from the automotive world where the flanges are on the pipe, and can't come off. So if you don't have flanges, you don't have a way to install it.
- Disconnect heater wire from wall outlet (5 seconds) and opt to let it fall instead of setting it on the ground. Stare in horror (20 seconds) as said cord falls the wrong way and hits the bottom of the left hard bag (that was only partially covered up) and puts a tiny nick/chip in the paint.
- Install HD chrome head bolt bridges on engine (2.5 hours - 1 hour spent looking for a hex stud insert that I dropped) - I'm breaking the rules on this one, and I'll probably pay for it later (which means I'll end up taking them off). I love the way these look, but I am afraid of what it's going to do with the air flow to the area in the middle of the heads. Had to dremel the outer side of each bridge so that the spark plug wire could be removed and put back on easily.
- Get out torque wrench in preparation for head pipe install. Remember it was broken from over 10 years ago, and was not replaced. Run to Sears to get a new one (1.5 hours)
- Finally start installing head pipe (1 hour) - Had wife help with holding and watching front part of the pipe so I could get it aligned in the first shot.
- Start re-installing heat shields on new header pipe (2 hours) - Yes, that's right - 2 hours. I could not get them to align like the way they were on the factory pipe. I realized it was a different pipe design, but I felt like I should be able to do it. Finally gave up and left them as they were. Overtightened the shield between the muffler and the upper shields, and put two small dents in it from where the clamp mounts were.
- Install cross-over pipe (30 minutes)
Fullsac Install - Day 3 (Wednesday)
- Remove old cores from mufflers (2 hours) - Yep, another 2 hours for something that most guys are getting done in about 30 minutes. I was completely paranoid of going too deep and going through the muffler wall (almost did on one can). Started wailing on the core trying to break it lose while the muffler was sitting on a small table. Forgot that I had left the Dremel sitting on said table, and watched it fall and break the grinding disks and bend the screw holding them on.
- Install wrapping with new cores (1.5 hours) - Yet something else that should have taken about 30 minutes. I wanted to use all of the wrapping so that the new exhaust wouldn't be much louder than stock, but just sound better. The first can went great. The second can I had to do 3 times before everything went in, and managed to get it stuck on the 2nd try which required pliers to pull back out.
- Install mufflers, heat shields, and end caps (1 hour) - Realized that the end caps have to go on before the muffler heat shields go on AFTER I put the heat shields on.
Fullsac Install - Day 4 (Today's schedule)
- Finish installing end caps and reinstall muffler heat shields
- Re-install right foot board
- Program ECM with new fuel map
- Re-install side covers and bags
It's been pretty disparaging that something that most guys are finishing in 4 - 6 hours is taking me 3.5 days to complete. While I'm no master-mechanic, I've done enough to consider myself to be decently competent (motor swaps, chassis rebuilds, etc). But, at least it will finally be done. Sorry how long this was, but if you were able to have a chuckle or two at my expense then it might be worth it.
Tru