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[GregKhougaz]

                   I'm no mechanic so I printed out Jim's instructions for the Fullsac installation and cat.  The instructions are perfect.  It does help to oil the exhaust joints before disassembly and reassembly so they slide off / on with ease.  Same for the cores.  Using oil / WD 40 to cool the bit often also helps.  Well worth the effort!!  Thanks Jim!  I'm starting to feel like a "disciple."

                   Result:  Great sound (not too loud but very deep), more responsive and definitely cooler engine.  Seems like the best bet, esp. in locations where they enforce the exhaust regs.  The Stock pipes are beautiful.  Most aftermarket pipes will be smaller and don't look right....  Bike seems to run very well.  I defer to those more knowledgable but Steve at Fullsac says no need for SERT unless you also get the heavy breather which I'm waiting on....  At full throttle, all EFI's go to rich so you should be OK. 

                    I have an extra 1.5" from McGills and another from Tool Barn (both unused).  (SOLD) Let me know if anyone needs them.  Thanks. 

[MikeD]

I'm worried that with drilling the cats, while the pipes are on the bike, will leave metal shavings in the pipe and eventually be suck back into the motor causing damage, any thoughts?

[GregKhougaz]

As Jim said,  after you have drilled and with the muffler still off, start the bike briefly, rev motor one or two times.  That should blow out anything there.  In an abundance of caution, we put a little oil and a rag and used a probe after.  Got nothing more out so I think it was clean. 

[Jim Kerr]

As Jim said,  after you have drilled and with the muffler still off, start the bike briefly, rev motor one or two times.  That should blow out anything there.  In an abundance of caution, we put a little oil and a rag and used a probe after.  Got nothing more out so I think it was clean. 

Greg, you are becoming a disciple.  Welcome to the flock.   

This is exactly right.  Run the engine without the mufflers and any dust will blow out.  Note, there will not be much, if any, shavings if you use the core bit I recommended.  It smoothly grinds so the core is preserved.  This is why you need oil.  It is a very slow and fine cut.  It isn't like a drill bit that creates shavings.  Another thing to note is the shavings couldn't make it into the engine in any case.  The cat is at the lowest point of the pipe.   You would have to be inverted to get anything up into the engine. 

[GregKhougaz]

Greg, you are becoming a disciple.  Welcome to the flock.   

Thanks Jim!  I have ordered the Heavy Breather and SERT and have a shop that will install & tune for $200.  I'll throw on a set of SE plugs and post the numbers.  I think I'll be happy...  for a while!  Nest time I get to Chicago we'll have to get that 

[Jim Kerr]

Thanks Jim!  I have ordered the Heavy Breather and SERT and have a shop that will install & tune for $200.  I'll throw on a set of SE plugs and post the numbers.  I think I'll be happy...  for a while!  Nest time I get to Chicago we'll have to get that 

Sounds like a great plan.  Ping me when you get to Chi Town. 

[sblair]

Jim and crew;
  Finally got my core bit today and went out to the garage and started drilling.  Took a little while and punched through unexpectedly.  pushed in and then pulled out.  Looked at my bit and no core!!!  Took the ole flashlight and the core was sitting right there where she was originally. 
   Well, we are in a pickle now...If I attempt to put the drill bit back it, it will just push it deeper.  So I figure, you are supposed to start it up and blow out any particles and that looks like a really big particle so what the hay!
   Turned on the ignition, hit the run switch and then hit the starter....nothin!  Try it again, nothin!  Scratched my noodle for a second ....aha bike was in gear.  What a neat little safety feature.  starter will not engage unless you are in neutral or have the clutch pulled in.
   Sooo started it up and POP out comes the core!!!  OK, sweatin time is over.  Cleaned up and put everything together and took it for a spin..  Damn quick with the canned map and we will see Thursday after the Dyno.  I'll post numbers but it should fall in line with everyone elses.

[tlr]

 

[GregKhougaz]

the core was sitting right there where she was originally. 
   

Had to get mine out with a clothes hanger.  If so, straighten it out and put a 1/2" hook on the end.  Then "fish" the pipe.  No problem.   

[Jim Kerr]

Jim and crew;
  Finally got my core bit today and went out to the garage and started drilling.  Took a little while and punched through unexpectedly.  pushed in and then pulled out.  Looked at my bit and no core!!!  Took the ole flashlight and the core was sitting right there where she was originally. 
   Well, we are in a pickle now...If I attempt to put the drill bit back it, it will just push it deeper.  So I figure, you are supposed to start it up and blow out any particles and that looks like a really big particle so what the hay!
   Turned on the ignition, hit the run switch and then hit the starter....nothin!  Try it again, nothin!  Scratched my noodle for a second ....aha bike was in gear.  What a neat little safety feature.  starter will not engage unless you are in neutral or have the clutch pulled in.
   Sooo started it up and POP out comes the core!!!  OK, sweatin time is over.  Cleaned up and put everything together and took it for a spin..  Damn quick with the canned map and we will see Thursday after the Dyno.  I'll post numbers but it should fall in line with everyone elses.

Excellent news!  Congratulations!  Can you tell a difference in performance?  I noticed it as soon as I pulled out of the driveway. 

Interesting about the ignition bypass.  My old bike would have taken off in gear if I hit the starter.  Probably a regulation somewhere that MoCo had to comply with. 

[LETS_ROLL]

                   I'm no mechanic so I printed out Jim's instructions for the Fullsac installation and cat.  The instructions are perfect.  It does help to oil the exhaust joints before disassembly and reassembly so they slide off / on with ease.  Same for the cores.  Using oil / WD 40 to cool the bit often also helps.  Well worth the effort!!  Thanks Jim!  I'm starting to feel like a "disciple."

                   Result:  Great sound (not too loud but very deep), more responsive and definitely cooler engine.  Seems like the best bet, esp. in locations where they enforce the exhaust regs.  The Stock pipes are beautiful.  Most aftermarket pipes will be smaller and don't look right....  Bike seems to run very well.  I defer to those more knowledgable but Steve at Fullsac says no need for SERT unless you also get the heavy breather which I'm waiting on....  At full throttle, all EFI's go to rich so you should be OK. 

                    I have an extra 1.5" from McGills and another from Tool Barn (both unused).  Let me know if anyone needs them.  Thanks. 

Greg, did you take any pics. during the installation.  Like for instance what is a 1.5" McGills and what and how to used it.  I've been keeping an eye on this as it seems very doable with great results.  My SERG ships in Nov. and I'm trying to get ready to work on it when it gets here.  Thanks in advance.  Oh yeah and what's the $$ for the Full Sac stuff.  You also mention Jim's install intructions and Cat.  Would that be possible to post?  Let's Roll

[Jim Kerr]

Greg, did you take any pics. during the installation.  Like for instance what is a 1.5" McGills and what and how to used it.  I've been keeping an eye on this as it seems very doable with great results.  My SERG ships in Nov. and I'm trying to get ready to work on it when it gets here.  Thanks in advance.  Oh yeah and what's the $$ for the Full Sac stuff.  You also mention Jim's install intructions and Cat.  Would that be possible to post?  Let's Roll

The how-to post is in the Exhaust/ECM section of this board.  Here's the link:
http://www.cvoharley.com/smf/index.php?topic=28086.0

[GregKhougaz]

Lets_Roll, 

          Did not take pics as Jim had already posted just about perfect instructions with pics and all information, including where / how to get the bit.  The cores were $109 from Steve at Fullsac if you tell him you're a CVO member.  Just take your time and you should not have any problems. 

Greg

[sblair]

Jim;  Yep...power was noticeable.  I already had the canned map installed but I still felt it.  Came back home smiling!!!!!

[Jim Kerr]

Jim;  Yep...power was noticeable.  I already had the canned map installed but I still felt it.  Came back home smiling!!!!!

I feel ya.  I smile ear to ear when I punch the throttle now days.  It is a blast!  Congrats!