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[gg]

I have a 2009 SE Ultra Classic with the 110" engine and the catalytic converter in the exhaust header. I want to replace the catalytic header with a stock 2009 non-cat exhaust header from a 96" engine. Any mechanical or size issues with doing this? Is it an exact swap? All information from those CVO'ers who have done this swap would be appreciated. Thanks

[michaelbmenaker]

I believe I read on this forum that the flange is different from '09 to '10 so the earlier headers will not work. Can anyone confirm?

[Sapper6]

Not sure why you would want to ask this question in the SESG forum

The 2009 exhausts are different from the 2010 CVO exhausts.

I cannot confirm for certain...   yet, but believe that there is an alternative to modifying your existing cat filled exhaust for a non-cat version through the Moco.  The best place to find this answer would probably be here:


Intake/Exhaust/ECM

Good luck.

[gg]

Didn't know I was asking on a model specific form. Sorry

[Sapper6]

Looks like this should answer your question.  Found this under the Exhaust Forum using the search function.

Hi guys, looking to go cat free and not have the flap valve we have on European headers.
Do you have the part numbers for the TC 96 that fit the 2009 SE4 and don't have cats?

Thanks
Jon

Jon, I used a 48 state domestic catless header the part number stamped on the bottom is 66848-09. Good luck with your install. I did mine last weekend. Good luck with your install. CAHDBIKER

[Sapper6]

Didn't know I was asking on a model specific form. Sorry

No problem... Hopefully we found what you were looking for anyway

[gg]

Thanks

[HOGMIKE]

I have a 2009 SE Ultra Classic with the 110" engine and the catalytic converter in the exhaust header. I want to replace the catalytic header with a stock 2009 non-cat exhaust header from a 96" engine. Any mechanical or size issues with doing this? Is it an exact swap? All information from those CVO'ers who have done this swap would be appreciated. Thanks

Yes

[gg]

Thanks Hogmike.

[Jon Seddon]

Looks like this should answer your question.  Found this under the Exhaust Forum using the search function.

Yes that's me, and it fits exactly on my 2009 SEUC

Jon

[gg]

Great, thanks Jon.

[jesse111]

I have a 2009 SE Ultra Classic with the 110" engine and the catalytic converter in the exhaust header. I want to replace the catalytic header with a stock 2009 non-cat exhaust header from a 96" engine. Any mechanical or size issues with doing this? Is it an exact swap? All information from those CVO'ers who have done this swap would be appreciated. Thanks

Have you considered the Fullsac X-pipe? You're going to have to re-map either way so at least with Fullsac you'd be bustin a serious move on performance increase.

Just a thought.

[gg]

Thanks again Hogmike and Jon, for the information about the non-cat HD header being an exact swap. Any tips or suggestions either of you have in removing what came on the bike and installing the replacement non-cat header?

[Jon Seddon]

I don't know whether your bike is a US or none US model.  The UK CVO and standard models have a exhaust valve on the end of the header pipe for noise regulations, I don't think the US do. 

Anyway if it's a UK bike and you replace with a US TC 96 you have to remove the bowden cable that would have attached from the stepper motor to the header and attach an active exhaust bypass device between the ECM and the stepper motor (It's just plug and play and stops fault codes cost about £20) - not a problem if you haven't got the exhaust valve anyway.

I got my TC96 headers ceramic coated.

I completely removed my whole system mufflers, crossover pipe and support (back of engine) and fitted it all back loosely at first.

The header support bracket under the right had side of the engine requires a deep socket to reach.

You'll need to undo your footboard to allow it to swing out of the way so you can get the header at the right angle to fit to the heads..


If you replace the header to head exhaust gasket (I haven't done it every time I've had the headers off), taper is out and be gentle fitting.

Don't  overtighten the header to head bolts.

Don't forget to unscrew and reattach the o2 sensors, before taking header off and after fitment, use a bit of high temp anti sieze on the threads (a very small amount).

It's really quite easy.

Jon

[gg]

Thanks again for the help with this question. I installed the new cat free header yesterday and it was very simple just as had been said on this message string. The hardest part was figuring out how to get a torque wrench on to the front cylinder lower flange nut to torque to spec. Then I remembered why I bought those articulated connectors from the wrench, which worked well.