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[Highwaystar]

I looked inside and It can be done inhumanely with a drill, hole saw and six pack. The method of best extraction would be answered best by some one who has done it. I do not want to leave left over material hanging on the wall of the header.  Is there a second cat in the lower tube or lower collector area that is not visable? I was told by our friends at Fullsac that it can be worth 15 hp (plus 1/34 muffler cores). Any one with any info? Thanks

[grc]

I looked inside and It can be done inhumanely with a drill, hole saw and six pack. The method of best extraction would be answered best by some one who has done it. I do not want to leave left over material hanging on the wall of the header.  Is there a second cat in the lower tube or lower collector area that is not visable? I was told by our friends at Fullsac that it can be worth 15 hp (plus 1/34 muffler cores). Any one with any info? Thanks

The only way I know of to totally eliminate all vestiges of the catalytic convertor is to buy the stock headpipe for the 49 state version of the TC96 model.  They don't have a cat.

Jerry

[partycrasher]

check out this link...............    http://www.cvoharley.com/smf/index.php?topic=27814.0

[bribe36]

The best, most efective, method would be to get a coring bit and drill it out in one piece. There is a post complete with pictures, directions even a source for the bit. I chose to go the cheaper way and do it with what I had available around the house. I used a 3/8" bit to drill holes around the edge, them I broke the thin joint between the holes with a screw driver. Them I cleaned it out with a 1 1/2" hole saw. There is very little evidence remaining on the pipe and the sound is improved greatly. Total time, under 1 hour. That includes removing and reinstalling the saddle bag and muflfer. Good luck

[Gone Fishin']

I looked inside and It can be done inhumanely with a drill, hole saw and six pack. The method of best extraction would be answered best by some one who has done it. I do not want to leave left over material hanging on the wall of the header.  Is there a second cat in the lower tube or lower collector area that is not visable? I was told by our friends at Fullsac that it can be worth 15 hp (plus 1/34 muffler cores). Any one with any info? Thanks

I am not an expert, but to me it looks like changing the piece of the exhaust against the same piece from a '96 engine would be the cleanest way to do it. The '96 engines do now have a cat in the exhaust, as far as I know.

Ride safely,
Louis

[Jim Kerr]

I am not an expert, but to me it looks like changing the piece of the exhaust against the same piece from a '96 engine would be the cleanest way to do it. The '96 engines do now have a cat in the exhaust, as far as I know.

Yep, the cleanest, albeit the most expensive and most difficult, way is to remove cat is to change the header pipe.  Drilling the cat only requires that the right exhaust is pulled, drill the cat and put it back together.  The header swap requires that the entire exhaust system is removed, new gaskets, etc.  At this point it would probably be better to wait until the after market manufactures release performance headers.   

[GregKhougaz]

          Bub has announces it's '09 Bub 7 True Dual system.  No price listed but it's got to be at least as much as the prior year's system, $870.  Fullsac cores:  $109 (w/ CVO discount).  McGills core bit:  $26.  Hanging out with a buddy, drilling out the cat, grinding out the stock cores and installing Fullsacs:  Priceless!!  Result:  Great sound (not too loud but very deep sound), more responsive and 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....

          I'm no mechanic so I printed out Jim's instructions.  They are perfect.  It helps to oil the exhaust joints before disassembly and reassembly so they slide off / on with ease.  Same for the cores.  Well worth the effort!!  Thanks Jim!  I'm starting to feel like a "disciple."

          BTW, after finding the bits unavailable for a couple of weeks, I have an extra 1.5" from McGills and another from Tool Barn (both unused).  Let me know if anyone needs them.  Thanks. 

Greg

[Jim Kerr]

The Stock pipes are beautiful.  Most aftermarket pipes will be smaller and don't look right....

Agree with Greg.  I've seen several after market pipes installed on the SERG's and they are usually off center and are an inch smaller than the original.  The problem is the skirt around the saddlebags perfectly frames the original exhaust.  It is very noticeable when they are changed to pipes that are smaller and off center. 

FYI, most slip on's also hit the axle nut or are darn close to it.  The wide tire and frame change cause problems for the 2008 and prior designs.  This is why most of them are not mounted in the center of the opening. 

[hard10]

I swear, I thought you guys were talking about removing dead cats:

[Jim Kerr]

We are! 

[partycrasher]

FYI--i just picked up a  stock 09 exhaust from a non cvo touring model ( non california model as well) off of ebay for $100. The head pipes fit right on perfectly-and there is no cat. I put my local dealer on notice that i was looking for a set and the service manager told me he has 2 noncvo baggers coming in next week for complete exhaust swaps....so check with your local service managers....

[GregKhougaz]

FYI--i just picked up a  stock 09 exhaust from a non cvo touring model ( non california model as well) off of ebay for $100. The head pipes fit right on perfectly-and there is no cat. I put my local dealer on notice that i was looking for a set and the service manager told me he has 2 noncvo baggers coming in next week for complete exhaust swaps....so check with your local service managers....

Good call, partycrasher!     

[Screamin]

FYI--i just picked up a  stock 09 exhaust from a non cvo touring model ( non california model as well) off of ebay for $100. T

So you're the one  . Glad someone from the site got it.

[LPFRAY]

FYI--i just picked up a  stock 09 exhaust from a non cvo touring model ( non california model as well) off of ebay for $100. The head pipes fit right on perfectly-and there is no cat. I put my local dealer on notice that i was looking for a set and the service manager told me he has 2 noncvo baggers coming in next week for complete exhaust swaps....so check with your local service managers....

Is this true?  If so why the difference between the CVO and the non CVO headers?

[Jim Kerr]

Is this true?  If so why the difference between the CVO and the non CVO headers?

CVO has a 110" engine that takes emissions over the legal limit.  H-D had to install a catalytic converter on the CVO models to keep them within EPA limits.