Print

Please login or register.
1 Hour 1 Day 1 Week 1 Month Forever
Login with username, password and session length

[charles05663]

Hello Everyone,

 

I am replacing my header with a cat-less one and am running into some issues installing it.    Is there some sort of trick to install it?

I thought the replacement might be off so I tried the original and it is the same installation issues.

Charles

[LarryB]

whats the problem?
did you remove the right floorboard?
did you seperate the crossunder from the head pipe?
you might want to use new gaskets on the head, make sure they are the SE ones.
Make sure you have a torque wrench.
maybe take a pic with the problem
oh ya, do you have enough beer?

[gg]

Hopefully you also have the service manual for the touring models which will also help guide you thru it. Unlike Larry, recommend you save the beer for after you're done.

[Gettinold]

Had a little trouble removing mine as well but after a little patience, it fell right aff there. Good luck 

[FLSTFI Dave]

For me, a cold beer helped with the patience in getting the head pipe back on

[charles05663]

Hello everyone,

Thanks for the replies.

I have removed the complete exhaust and I am trying to install the cat-less header from a 2009 touring 96" engine.  I have all of the HD service manuals and part manuals (5 total).

1) removed the complete exhaust and right floorboard and rear floorboard support bracket.  The front floorboard support bracket looks like a pain to remove/re-install so I did not remove it; I just removed the floorboard and rear support.

2)  I do have a torque wrench

3)  I replaced the original gaskets with HD part # 65324-83B.  Both the FLTRSE3 and the Touring Models parts catalog list the same part number.  LarryB, do you know of a different part #?  I know when I installed the gasket, it was a tight fit and it seemed to crumple a little bit when they were inserted.  I am assuming they are just pressed in with your fingers, no special tool needed.

4) Although the service manual did not tell me to, I applied anti-seize compound to the header studs.

The problem I am having is with the installation of the header.  I get the front header started and the two flange nuts in place.  When I try and "roll" the pipe on the rear cylinder I cannot get it to lineup or get the exhaust manifold clamp on.

Needles to say at this point the gaskets are all torn up and I am going to have to replace them.  I did pickup two sets so I don't have to drive 90 miles round trip to the nearest HD shop.

I would very thankful for any tips on installing this.  I will admit that I do not have very much repair experience but would like to learn to do my own work on my SERG.  Picking up any tools needed is not an issue; I just want to do the job correctly and as best that I can.

Thank you.

[Fired00d]

Your mention of the gaskets made me think of something.... Did you get the old gaskets out?? Not sure if that could create the problem you are having but I remember that someone in the past had left or forget to get the old gaskets out of the heads.

 
Ride Safe,
Fired00d
 

[charles05663]

Hello Fired00d,

I did get them out.  Used a hook and dug into them and the pulled out fairly easily.

Charles

[Fired00d]

Hello Fired00d,

I did get them out.  Used a hook and dug into them and the pulled out fairly easily.

Charles

Ok, just a thought... hope you find out (soon) what is causing the problem.. Good luck.

 
Ride Safe,
Fired00d
 

[moscooter]

 
I must admit I did not read every entry here........but will add that when installing a complete exhaust system,  you need to start the tightening at the header pipes (at the cylinders) and then work your way back with fitting the remaining pipes/mufflers/brackets.......tightening them down just a bit at a time till the whole thing lines up and fits......before you tighten every thing else up. 

[charles05663]

I guess my question in a nutshell is, is there any tricks to getting the header installed?

[Highjagger]

Try to bring the flange nuts in place without force and play with them with the loosely pipe hanging down ( not mounted anywhere ) twist the flanges till they get easily in the right places where they should be , then screw a little the front flange first then back flange then a little bit tighter , then the rest mounting to rear like it was said here and then really tight at the end .

[LarryB]

sorry I was away from the puter to respond. the prob you are have is the rear bracket of the rider floorboard. yes, it is hard to remove, but it is in the way and won't let you roll the pipe into place.
ya can either rotate the bracket counterclockwise or, remove it. try going at it from the left side of the bike with the ratchet and extension and hex bit. good time to add those floorboard extensions. hope this helps.
the gasket really needs to be pressed into place, by hand of course. use care when doing this.

[2UP3DOWN]

It's been roughly six months since I did that mod, but I do remember a few areas where I did have some trouble.

1. Replacing the header gaskets.  It's a ridiculously tight fit.  After removing the original gaskets, use emery cloth to lightly sand down the rough surface and clean the edges before inserting new gaskets.

2. The header pipe is installed by inserting the front header pipe loosely onto the threaded stand-offs and then carefully rock the entire header pipe into place until the threaded stand-offs insert into the rear header.  Then work back and forth tightening both front and rear until both headers are torque properly. The key is lots of patience.

After running the bike for a few miles, don't forget to re-check the bolt tightness.

I also found that replacing the gasket in the cross-over pipe was the worst part of the job.  The new gasket really didn't want to go in and the pipe clamp really gave me fits when trying to re-install it

You might want to forgo the beer and go straight for the heroin shot…   actually now that I've done my first exhaust removal/re-installation I feel much more confident in knowing how to do this in the future. It's really not so bad once you get one under your belt.

[charles05663]

I got my cat-less header from the local HD shop.  It was taken off a 2009 bagger.

I know everything is possible, but what are the chances it is not the same?  I found that the cat header fits but the cat-less one does not.  I wonder if it got damaged when I had it Jet-Hot coated.  Is there methods to fit a header?

I did try and measure them side by side and if they are off I can't really see it.  It appears the cat header is 1/4 wider then the cat-less header.