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[phattey]

I've done all kind of DIY stuff, but never a head pipe install on a bike. Is it a one person job? Are there any special tools needed..I've got jsut about anything, including air tools.

What about the heat shields, put them on before install..?

Any real gotcha's folks may wanna share...? I know when i get home and the stuff's sitting there I'll be all about chilling the beverages down a bit and breaking out the tools. But want to ensure it's a relatively painless effort...my bike has only 500 miles..so maybe things'll come off easily..

The tuner and baffle I'm sure will be easy...the headpipe's kinda freaking me out..

[catz66]

Just a bolt on. Remove the old one and install the new. Install the heat shields before installing the head pipe. Leave them a little loose so you can align them after head pipe is installed. It is a very easy install.

[phattey]

Ok...that's sounding promising...I guess where i feel less confident is prying out the exhaust gaskets and trying to get the new ones in...I've heard that can be a challenge.

[mjb765]

Ok...that's sounding promising...I guess where i feel less confident is prying out the exhaust gaskets and trying to get the new ones in...I've heard that can be a challenge.

Nah...a small pick or screwdriver and they come right out.

[phattey]

yeah...I have a bunch of gasket removal picks...mostly used for my little 1971 Honda CT-70.

[BUCKNUT GREG]

yeah...I have a bunch of gasket removal picks...mostly used for my little 1971 Honda CT-70.

With such little mileage...I wouldnt remove the exhaust gaskets.  I didnt and just did this mod last weekend.  No problems what so ever.  Oh Yea the tip came from the Fullsac Guru himself...go figure.  I put the heat shields on last.
This gave me more room for the tightening of the bolts  to the exhaust ports.  I do have lowers and the bottom bolt on the
front needs to be done by a rachet ranch unless you have them thar fancy tools,  I guess.  Good luck and you'll love
the improvement. 

BUCKNUT 

[phattey]

Yeah that's what I thought on the gaskets, especially since fullsac didnt provide any...i thought alice said EVERYTHING was in the kit...but no gaskets.

anyway, took me about 2 hours to put the 2 inch baffles in. cranked it up and couldnt believe the difference. these pipes now sound jusst like the rineharts on the 103 stgIII motor. we fired up the 103 and listened for a sec then fired up the cvo and they were almost dead on in similarity. having them side by side you could really do the comparison.

i'm too pooped to do the head pipes tonight, but it looks easier than messing with the baffles was.

i did notice that the air volume is much more on the right side pipe than the left. maybe due to some of the packing came out when working on it and the left one none of the packing came out.

there's also no instructions on the tts install...any tips..?

[BUCKNUT GREG]

Yeah that's what I thought on the gaskets, especially since fullsac didnt provide any...i thought alice said EVERYTHING was in the kit...but no gaskets.

anyway, took me about 2 hours to put the 2 inch baffles in. cranked it up and couldnt believe the difference. these pipes now sound jusst like the rineharts on the 103 stgIII motor. we fired up the 103 and listened for a sec then fired up the cvo and they were almost dead on in similarity. having them side by side you could really do the comparison.

i'm too pooped to do the head pipes tonight, but it looks easier than messing with the baffles was.

i did notice that the air volume is much more on the right side pipe than the left. maybe due to some of the packing came out when working on it and the left one none of the packing came out.

there's also no instructions on the tts install...any tips..?

The gaskets were taped inside the box even though I did not use them.  They are in a little baggy with there buisness card.  You will get more flow from the right side then the left side due to design.  Good luck on the headers.  Oh yea the instructions are on the software.  Hope this helps.

BUCKNUT 

[rayson56]

Instructions are on the disc thats in the box with the tuner. You need to upload this into your laptop before you start. If I remember right they are in PDF format. Your gonna love this setup.

[dave29]

I did three sets of headpipes for myself and friends. You can do it by yourself although two people makes it easier. I found that not toghtening any bolts until you get everything in place makes the job easier. This is especially true when it comes to the crossover pipe bolting to the mount on the rear of the engine. Take your time and remember to NOT tighten the heat shields too much or they will dimple.
Have fun.

[phattey]

yup...just finished the headpipe...super easy..!! yay.

now i gotta figure out how to install the map steve provided. i've got all the software installed on my laptop, i've read over things 100 times but i may not be getting it. so i'll back away and get a little lunch and a beer and i bet it comes to me..

any tips..?

[RedEagle]

one tip is dont over tighten the heat shields.  They will crack when they get hot.  I learned this on my Road King.  So when I did the FullSac conversion I made sure to torque the heat shields to their spec.  I think its about 15 inch lbs, whatever it is in the manual. 
Have fun its pretty easy cutting the baffle out and removing it is the hard part (not that hard) just be careful.
You will Love the results.

[Midnight Rider]

yup...just finished the headpipe...super easy..!! yay.

now i gotta figure out how to install the map steve provided. i've got all the software installed on my laptop, i've read over things 100 times but i may not be getting it. so i'll back away and get a little lunch and a beer and i bet it comes to me..

any tips..?

If you got the proper cable with the TTS...no problem.  Hookup is under the left side cover, towards the bottom.  After installing the software on your laptop, be sure to do all the updates, ESPECIALLY the USB Driver updates...otherwise, the correct com port will not be shown on your computer.  Be sure to upload what's already in the ECM and save it, before you download the map Steve sent you.  Once you get it to talk to the ECM, it's pretty straightforward.  You will love the results...

[phattey]

all done...pretty easy actually the entire install.

not sure if I actually prgm the bike with steves map. feels and sounds no different. i guess i gotta get out and ride it a little more to see if the heat is down...which maybe was the primary focus of the map - to richen it up some.

pretty good bit of deaccel poping..

may mess with it some more tomorrow. had enough today...time for dinner and a Knob Creek...

[Midnight Rider]

It's pretty easy to verify that you have the correct map in the ECM.  My bike has a very slight amount of decel pop when it's cold, but nothing that concerns me.  When it warms up, no popping...throttle response is MUCH improved, and my seat of the pants Dyno says it has more TQ/HP as well.