Print

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

[bigchuck]

I will be receiving dx pipe , 2" baffles and TTS today. I've seen videos on baffle install but little on pipe removal and install. Any suggestions to make job easier? Gasket included? Use of locktite or antiseize ? With the in formation I found on this site I'm confident in my choice of using Fullsac and thank you all.
Parts going on 2015 CVO limited bone stock.

[deldago]

I installed mine about two years ago and made the mistake of trying to replace the gaskets. After struggling for a half hour to get the front one back in place I left the rear one alone. Everything has been fine since and I have one brand new gasket in stock. I got the floorboard off and removed the factory pipe and loosely installed the whole system before tightening anything up. It fit very well with no wrench throwing or cussing. I started to grind the welds off the baffles with a dremel but ended up borrowing a die grinder with a bur bit and it went much quicker. Just be careful you don't grind too much and go through the outer pipe. Keep tapping the baffle back into the pipe every so often to see if the welds pop loose without going too far. Once it slides forward a little clean up any left over welds to allow the baffle to slide out the end without hanging up on them.Have fun and enjoy a few brews when done to celebrate your accomplishments!

[GregKhougaz]

I've done three installs on Rushmore CVO'S but am no expert.   If your bike has very low miles, you can reuse stock gaskets.  Otherwse, examine carefully.  Did not need locktite nor antiseize but be mindful of torque values and order of what gets tightened first, etc.  The touring service manual is very helpful.  WD-40 helps with disconnect and assembly. 

Make sure you label front and rear O2 sensors and properly route wires to new location. You may have to pull out slack to make them reach.  You will need to twist the sensor ends in the opposite direction before screwing in.  If you're using the packing and screens, use the stock packing from the left side and cut in half.  Packing fits outside of screens which should push packing out against the muffler cans. 

Here is an old thread but very helpful:   Installing Fullsac Baffles on 09 CVO Road Glide

[bigchuck]

Thank you both. I learned from both of your posts.

[skratch]

Make sure you label front and rear O2 sensors and properly route wires to new location.

i find it useful to remember, 'black is back'.....

[GregKhougaz]

i find it useful to remember, 'black is back'.....

I think mine were both black.

[Fullsac Performance]

No issues leaving the original gaskets in place, I never change them on a first time header swap.  I would however highly recommend cutting the small zip ties and unplugging the 02 sensors from under the right side cover and removing them with the pipe. Use a small amount of anti seize on the threads and re install in the DX on the bench. They are not impossible to damage and the tip must remain free of all anti seize oil etc. Black to the back cylinder as previously stated. Carefully route the wires around the clutch line after the header is installed. Tighten the tranny bracket before the exhaust ports. Be sure its fully engaged or balls deep as we appropriately say at Fullsac Performance. Exhaust ports are next. Be sure to loosely install the cross under and left muffler before it gets tightened. Your home free from there!

Ride safe

Merry Xmas!

Steve@fullsac.com

[TNCarters]

The split collars on the head connection flanges always give me a problem moving them from one pipe to the other.  Whats the right way or right tool to deal with those?  Its probably in my service manual but have not looked for it yet. 

[Fullsac Performance]

The split collars on the head connection flanges always give me a problem moving them from one pipe to the other.  Whats the right way or right tool to deal with those?  Its probably in my service manual but have not looked for it yet.

I pull them off with regular old pliars by grabbing them at the end and unrolling them.
Back on the same way. Be sure to inspect them for concave from previous over tightening and reverse them if they have taken a set.

Steve

[bigchuck]

Thanks to everyone for their advice. I've installed header and removed old baffles. A high quality carbide bit in a die grinder sure saves a lot of time. Started with a cheap bit then found my good one. 6 times faster at least. Left side packing was all screwed up from factory installation. Luckily the right side was fine with 2200 miles on bike. Also leaving original exhaust gaskets in place. The project will have to be put on hold until I get back in town (truck driver). And thanks to Steve for making such a great product and the great customer service he provides. I believe this is one time I won't be second guessing a product I've purchased for my bike. The forum discount and year end free shipping was cool also.

[bigchuck]

Disappointed I didn't get dx pipes with both O2 sensor sizes. Steve wasn't in and I guess I didn't ask the right questions. Thought I researched fully. No mention on website about being able to get a better tune with both sets. I should have waited to talk to Steve and not worry about getting parts in time to put on over Christmas. Not sure why the even offer them both ways. Is anyone really worried about saving the 20 bucks?

[Chains]

I did change my gaskets since I was replacing an aftermarket pipe system with the DX pipe. No issues, Fullsac pipes come with new gaskets.