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[DPnSD]

I had a set of CVO mufflers re-cored (2") by Steve at Fullsac.  I'll be putting them on myself, but still deciding on re-tuning options.  In talking with my HD service mgr., he seemed concerned about exhaust leaks and the potential power loss.  Said I should use high-temp sealant and new clamps (either HD or aftermarket that provide a better 360 degree seal).  In all the threads I have read related to muffler changes, I have not seen any comments about this.  Has anyone had problems with leaks after removing/replacing mufflers?

Second question, I am not removing the cat at this time, is there a single map download the dealer can do when he does the dyno? (a cheaper option)  Or I am better off just getting the SERT? 

Thanks for the input.

[Twolanerider]

I had a set of CVO mufflers re-cored (2") by Steve at Fullsac.  I'll be putting them on myself, but still deciding on re-tuning options.  In talking with my HD service mgr., he seemed concerned about exhaust leaks and the potential power loss.  Said I should use high-temp sealant and new clamps (either HD or aftermarket that provide a better 360 degree seal).  In all the threads I have read related to muffler changes, I have not seen any comments about this.  Has anyone had problems with leaks after removing/replacing mufflers?

Second question, I am not removing the cat at this time, is there a single map download the dealer can do when he does the dyno? (a cheaper option)  Or I am better off just getting the SERT? 

Thanks for the input.

You write that you are not removing the catalyst "at this time."  Are you planning to?  If so your best/most efficient tuning option is to wait.  Get whatever you're going to do done together and have it tuned once for that configuration.  Tuning (or even dealer downloads) is expensive.  Don't bear the cost more than once unnecessarily.

[fourstar]

Said I should use high-temp sealant and new clamps (either HD or aftermarket that provide a better 360 degree seal). 

I think he's stroking you with this sh!t.  You should probably replace the gaskets at the exhaust ports, although I have gotten away without doing so a few times.  The only other gasket I can think of is where the crossover connects to the header pipe, and I haven't replaced that one yet, nor have I replaced any of the clamps, and I have no leaks.  And there is no "high-temp sealant" for the exhaust system.  Spend $40 and get a service manual, read and follow the procedure.

+1 on Twolanerider's post above.  And if you're fairly competent with the computer and understand the tuning process, you can buy a tuner and do a pretty good job of tuning it yourself. 

[dartman]

I had a set of CVO mufflers re-cored (2") by Steve at Fullsac.  I'll be putting them on myself, but still deciding on re-tuning options.  In talking with my HD service mgr., he seemed concerned about exhaust leaks and the potential power loss.  Said I should use high-temp sealant and new clamps (either HD or aftermarket that provide a better 360 degree seal).  In all the threads I have read related to muffler changes, I have not seen any comments about this.  Has anyone had problems with leaks after removing/replacing mufflers?

Second question, I am not removing the cat at this time, is there a single map download the dealer can do when he does the dyno? (a cheaper option)  Or I am better off just getting the SERT? 

Thanks for the input.

Ive changed a ton of mufflers over the years, a good sealant does stop the leaks that sneak out of the inlet slots
Ive used this for years with good success a little placed in the slots with the clamp in place eliminates any chance of leakage. http://www.permatex.com/products/Automotive/automotive_gasketing/gasket_makers/auto_Permatex_Ultra_Copper_Maximum_Temperature_RTV_Silicone_Gasket_Maker.htm

[grc]

One note I'd like to add to the conversation.  Yes, it's possible to get leaks after removing and reinstalling a muffler.  However, if you don't enlarge the opening in the muffler getting it off, and the header pipe hasn't been crushed or bent, odds are you will do just fine without any special sealants.  Make sure you use new clamps, as the ones currently used by Harley are basically once and done.

I personally use a high temperature anti-seize compound on mine, so I won't have to destroy the pipes getting them apart two years later when I need to get the exhaust out of the way to perform some other repar.  Maybe that has a secondary effect of sealing any tiny leak paths.   BTW, sealants aren't used in production on exhaust systems.  Wonder why your guy thinks he needs them, but the factory folks don't?

Jerry

[Smuuth]

If the only thing you are doing at this time is replacing the slipon mufflers, you should be fine reusing the clamps that are there now.  I second the idea of using an anti-seize compound between the muffler and the headpipe.  It will make it easier the next time you remove them. 

If you have to remove the crossover pipe which goes under the bike from the right side to the left, there is a gasket where it attaches to the right side header pipe and I would recommend replacing that gasket if you remove it.

[gg]

DPnSD, I recognize you live in CA, but why would you put in fullsacs and NOT get a new cat free header too? Your going to have lots of heat by keeping the cat header in place. You should consider asking a non-CA CVO member to help you acquire a non cat header and then get Steve's map for the CVO engine and install it. Has CA started checking motorcycle emissions? With the way their budget crisis seems headed, they've got bigger fish to worry about than a few motorcyclistas.

[gg]

DPnSD, the non cat header can be had from Zanotti HD for about $315 plus shipping the last time I checked.

[DPnSD]

All, thanks much for the input and suggestions.

fthngrg,
Probably just overly paranoid about the cat-police here in CA.  Not sure how serious they are going to be enforcing the bill they just passed.  Main reason for the fullsacs was improvement of the sound of the bike, secondary benefit being more power (but comparing this bike to my '05 RK, don't really need more power     Afterall, I have the orange-black which is the fastest!  ) 

[fourstar]

All, thanks much for the input and suggestions.

fthngrg,
Probably just overly paranoid about the cat-police here in CA.  Not sure how serious they are going to be enforcing the bill they just passed.  Main reason for the fullsacs was improvement of the sound of the bike, secondary benefit being more power (but comparing this bike to my '05 RK, don't really need more power     Afterall, I have the orange-black which is the fastest!  ) 

With practically every government entity facing budget shortfalls, potential layoffs, hiring freezes, etc., I doubt that enforcement of this will be a high priority, even if the governator signs it. 

[gg]

DPnSD and Fourstar, that's my point. California has lots bigger issues than a few motorcyclists not following the letter of the law. Do police cars have test equipment in their vehicles? I doubt. follow my earlier suggestion, buy the non cat pipe, open it up and cool it oof and enjoy it.

[grc]

DPnSD and Fourstar, that's my point. California has lots bigger issues than a few motorcyclists not following the letter of the law. Do police cars have test equipment in their vehicles? I doubt. follow my earlier suggestion, buy the non cat pipe, open it up and cool it oof and enjoy it.

What he said.  Just make sure you save all the removed parts, 'cause the next step after this one will be the annual or semi-annual sniffer test required to get your registration.  It didn't get passed this year, but once (if?) the economy starts to improve the clean air folks will be back pushing for even tighter restrictions.

Jerry

[Ed Ramberger - One_Screamin_Eagle]

I had a set of CVO mufflers re-cored (2") by Steve at Fullsac.  I'll be putting them on myself, but still deciding on re-tuning options.  In talking with my HD service mgr., he seemed concerned about exhaust leaks and the potential power loss.  Said I should use high-temp sealant and new clamps (either HD or aftermarket that provide a better 360 degree seal).  In all the threads I have read related to muffler changes, I have not seen any comments about this.  Has anyone had problems with leaks after removing/replacing mufflers?

Second question, I am not removing the cat at this time, is there a single map download the dealer can do when he does the dyno? (a cheaper option)  Or I am better off just getting the SERT?  

Thanks for the input.

The factory torca clamps are a designated one time use but everyone re-uses them.  Then when mufflers slide back and have hard contact under saddlebags or fall off on Dynas (just saw this AGAIN 2 days ago and had to tell the rider what the last shop did) because the clamps were re-used and no one riveted them (older)people wonder why.

Ultra copper is for gaskets such as water pumps, valve covers etc.  There is actually a red colored RTV specifically for exhausy (ever see it in a set of SE Kerkers???

You will get no power loss from a little leak at the muffler to pipe connection.