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[wreckman 42]

Well I finally got around to taking off the cat head pipe and installing the non-cat head pipe I bought off ebay. Having a he!! of a time getting it back without messing up the gaskets. I have a new set of gaskets coming and will try again. Any tips on getting the pipe back on and getting a good seal on the gaskets? I tried taking off the lower pipe mount so I didn't have to deal with it and found that I couldn't get it back on with the pipes on. I need some advice.

[fourstar]

If your gaskets are getting thrashed, replace them.  I didn't and had a leak so I had to redo the job.  Start with the front pipe.  Tip the assembly slightly to get it started.  Once the front is in, bring the back in.  Loosely put the flanges on with bolts finger tight.   
Before you tighten up any nuts or bolts, get everything on (lower bolt, cross-over, slip-ons) with bolts finger tight.  Then start at the flanges and work your way back.  The flanges have to be torqued in stages and in a specific order.  Check the manual.  It has pretty specific instructions as well. 

[TN]

follow the procedure in the manual.

i learned this the hardway.



good luck


TN

[GregKhougaz]

Men reading directions???     What's next, GPS?       Oh yeah.   

[d o g o l s]

Well I finally got around to taking off the cat head pipe and installing the non-cat head pipe I bought off ebay. Having a he!! of a time getting it back without messing up the gaskets. I have a new set of gaskets coming and will try again. Any tips on getting the pipe back on and getting a good seal on the gaskets? I tried taking off the lower pipe mount so I didn't have to deal with it and found that I couldn't get it back on with the pipes on. I need some advice.

its easy just take me 50 min to change

[gg]

Manual says use NEW gaskets when installing header. Gaskets are chaeper than your time redoing it later.

[d o g o l s]

Manual says use NEW gaskets when installing header. Gaskets are chaeper than your time redoing it later. 

[copbike 02]

What is the procedure for the head pipes on torquing them I had to order the manual it's not here yet? I would like to change my pipe tonight. Thanks for any help guys going to put the new Vance & Hines head pipe on

[Highjagger]

its easy just take me 50 min to change

Wow ,
I guess it would cost me 3 hours then 

[LarryB]

I change gaskets each time I re-install pipe, very cheap do, get the Screamin Eagle gaskets
Hold the pipe in place, slide flange over bolts. I use red locktite. put the nut on that it the hardest to reach first and run it up to hand tight, you can use socket and extension to do this but don't ratchet yet.thread other nut on and tighten to about 20 in lbs. Now before you tighten these all down, make sure all your secondary support brackets line up. start those nuts/bolts. Now go back and tighten head pipe to cylinder heads to 110-120"lbs. not FT lbs. do not over torque this. If you break it, it's a biotch. ask me how I know this, on second thought, don't.
what I now do is torque it to 110"lbs, get all else together and start it, check for leaks, bring it up to temp then shut dont. tighten to 120"lbs, the expansion from heat allows a good seat.

[gg]

LarryB, would you please provide some detail about how you go about checking for leaks? I have the HD touring repair manual and it talks about using some sort of Propane tank and tubing apparatus, which I don't have. Do you have an alternate method other than visual inspection? If you do, please tell us about it. Thanks

[ragrep]

 Always replace the exhaust gaskets whenever you remove the head pipes. Seems we all have our own process of installing the pipes- biggest thing to keep in mind when you position the headers is not to scratch up the cylinder fins or the other painted surfaces around or below the mounting area- so lay some towels under the mounting area incase the pipe come loose when you are working on the other end. I would NOT use RED LOCKTITE-  or any locktite. 1. its not called for in the manual, 2. its unnecessary- I have never had one come loose 3. Good luck getting them off if you ever have to remove the head pipes again. Take care not to crimp or distort the gaskets when you install them. Buy one extra to keep on hand in case you chernoble one- it sometimes happens when you first learn how to install them.

Attached are the two pages in the 09 manual that leads you through the installation process-

[ragrep]

page

[LarryB]

LarryB, would you please provide some detail about how you go about checking for leaks? I have the HD touring repair manual and it talks about using some sort of Propane tank and tubing apparatus, which I don't have. Do you have an alternate method other than visual inspection? If you do, please tell us about it. Thanks

when you start the bike up run your hand around the area, careful not to touch it. if there is a leak you will feel a wiff of air at the point. sometimes you might even hear the leak. there is a product called canned smoke that I use to inspect smoke detectors, that works well also. No real science here.
As far as the locktight RagRep, I use a very small amount at the top of the bolt. I do this because so many times while doing routine service, I found the nuts to have gone -out of torque. I know this is caused by expansion/contraction, but I just feel better knowing there is a little extra protection. never have had an issue with getting them off.
Key things is to have a good torque wrench and insure of the setting. exhaust bolts and EZ outs are not friendly,

[ragrep]

Larry- intersting idea with the Locktite on the exposed threads after the nut is on- never thought of that.

fthngrg>>Checking for leaks- you can also use a punk stick/incense stick or one of those extended reach lighters (be careful with the flame) and check around the bolts- with the lighter you can see the flame move or snuff out.