Header install ?

[hulkss]

I plan on installing the headers myself and have been doing A LOT of research and some of the things I am reading conflict. I do have a service manual (bought it before getting the bike), and I do have a couple of concerns.

Practice installing the head pipe with the old gaskets. Follow the service manual procedure and manufacturer instructions.

The exhaust gaskets are pressed into the ports. Removing them will destroy them. Press in new tapered ones (like the HD parts) with the tool from Jims. Jims 788

Check the header flange torque with the engine cold after a couple rides (heat/cool cycles).

The circlips hold the header flanges onto the pipes. I get 'em off with a vice grips. Carful not to over bend them.

 

[Klmack]

That's valuable info- thank you-

 

[paul65k]

Just changed mine and never had to touch them with no leaks. Just do it Blue if you have a bunch of material stick to the stock head pipe then maybe an issue if not put the new pipe on.

Same here....my boke had ~3K miles when I did it and no issues.....I agree just do it and then check for leaks

 

[blkbrd]

I've always replaced the crush gaskets when I do headers. It's easy and it's good piece of mind knowing that the job is done right. You'll have easy access to them while you're replacing the headers, so why not just do it right? As far as torquing the headers to the jug, do not over tighten them! This is a big problem. I've seen lots of people replace headers that over tighten the bolts. What happens is the threaded cylinder that goes in the jug ends up spinning if it's over tightened. This means that the header will not be secured. The only way to fix this is to get the jug retapped and put another threaded cylinder in. Hope this helps you.


Sent from my iPhone using Tapatalk

 

[Klmack]

I do know that you need to get a good 'feel' when loosening the flange nuts. I do this by getting the socket on the nut and sort of looking away when I'm loosening so I can feel how tight they are, then replacing with a torque wrench. I would rather have to deal with re-setting and re-torqueing due to an exhaust leak than having to replace a flange stud.

 

[Bluebowtie]

I still have not installed my head pipes. I've been slacking I know. It's hard to change head pipes when it's always hot.


Sent from the mobile leash

 

[Bluebowtie]

So I installed the head pipes tonight. Rear cylinder seems to run kinda rough and spit and sputter a bit. Front runs smooth. RPM are jumping around just a bit also. Any ideas what I screwed up. LOL.

This mofo barks now!


Sent from the mobile leash

 

[Spazz]

Give it a run... you have opened it up to breathe. Let the ECM adjust a bit, she should calm down

 

[Bluebowtie]

Give it a run... you have opened it up to breathe. Let the ECM adjust a bit, she should calm down

Correct me if I'm wrong but wouldn't both cylinders run rough if it was just the header installation causing the issue.


Sent from the mobile leash

 

[Spazz]

Correct me if I'm wrong but wouldn't both cylinders run rough if it was just the header installation causing the issue.


Sent from the mobile leash

Yes and no.... you have changed the flow and decreased backpressure.... it has to re-learn that now. How can you tell if just the rear cylinder is acting up? You running true duals? ( that would be the only way I can figure )

If that is the case.... you may want to reseat the flange in the jug... just loosen everything, ensure the flange is even... alternate side to side until torque spec is reached.

Did you replace your gaskets or at least they were in good shape?

 

[Bluebowtie]

Yes and no.... you have changed the flow and decreased backpressure.... it has to re-learn that now. How can you tell if just the rear cylinder is acting up? You running true duals? ( that would be the only way I can figure )

Yes I installed dresser duals.


Sent from the mobile leash

 

[Spazz]

Yes I installed dresser duals.


Sent from the mobile leash

LOL... you replied as I was editing... go back and read my additional comments....

 

[Bluebowtie]

Header install ?

LOL... you replied as I was editing... go back and read my additional comments....

I did not replace the gaskets. There was no gasket material in the stock head pipe. Kinda winging it it's the first time I have installed a head pipe on a HD.

I could not feel any exhaust leaks at the flanges. What the bust way to check for leaks?

Sent from the mobile leash

 

[Bluebowtie]

I tried to do a video but damn phone won't record the audio cause it's too loud. LOL


Sent from the mobile leash

 

[TomA]

Looks good BB I like that blacked out look. Buddy had full exhaust installed on his bike while we were in Arizona last and it took about 100 miles to settle in so go ride it and have fun. He kind of freaked out as it was only getting about 20 MPG until it settled in and starting running right. He put on the Freedom performance black true duals and they have a sound of their own.

 

[hulkss]

What's the best way to check for leaks?

Have the bike parked and idling in your garage. Get a nice cigar and blow some smoke gently at the header flanges.

 

[Bluebowtie]

Looks good BB I like that blacked out look. Buddy had full exhaust installed on his bike while we were in Arizona last and it took about 100 miles to settle in so go ride it and have fun. He kind of freaked out as it was only getting about 20 MPG until it settled in and starting running right. He put on the Freedom performance black true duals and they have a sound of their own.

Thanks Tom!

Have the bike parked and idling in your garage. Get a nice cigar and blow some smoke gently at the header flanges.

That I can do.


I'm also going to reset the stored air fuel register manually with the Powervision and see what happens.


Sent from the mobile leash

 

[2015amberwiskie]

My bike ran rough immediately after putting on the Fulsac DX header. It concerned me at first, then it smoothed out after a few miles.

I reused the original gaskets in the head. The bike only had about 1000 miles at the time, now it has about 3500 now with no issues.

 

[Spazz]

O2 sensors do matter.... black plug O2 sensor is for the rear cylinder and gray plug is for the front cylinder

Sent from my Note4 using Tapatalk

 

[Fallguy]

Looks great and are you using a piggyback device or installed a new e.c.m. ? Could anyone further answer about the stock e.c.m. adjusting after exhaust and a/c changed.. I just downsized to the 2inch baffles from the 2 1/2 inch baffles because I lost all of my bottom end.. Gonna take it out for a test in an hour.

Just got back after a 60 mile test ride and huge difference in bottom and midrange pulling ! Also noticed a big improvement in gas consumption..