Arrrgh!

cactusjack · 03-30-2014, 12:39 AM

Since AZ did away with mandatory motorcycle emission testing last year, I decided to replace my stock header pipes to get rid of the catalytic convertor that cooks the back of my right leg. I ordered a set of V&H Power Duals from Fuel Moto and Fedex delivered them yesterday. So i started replacing them this morning.

I removed the stock exhaust and then did some detailing with the pipes off as it allows me to get to areas that are nearly impossible to clean with the pipes on. Then I installed the heat shields on the header pipes. I got to the step in the instructions where you slip the exhaust flanges over the new pipes and one of pipes is too large for the flange. They aren't split flanges like on a Kawasaki, they slip over and then you install a circlip which keeps the flange from coming off the end.

So now I am stuck. I need my bike this week because I have a training class in downtown Phoenix and if I ride the bike I can use about 27 miles of HOV lane, and it is much faster and better than driving my truck.

I will probably have to reinstall my stock exhaust tomorrow and then take up the issue with V&H on Monday. They are probably going to have to send me a new header assembly, because I don't have a magic flange stretcher.

**markclark57** · 03-30-2014, 01:29 AM

I know a local plumber that could give you a helping hand on Monday.

Loafer · 03-30-2014, 05:54 AM

Now that is a great idea!! Way to go Mark!

dshelly · 03-30-2014, 08:11 AM

Can you post a pic Scott? How much too small is the flange?

Dave · 03-30-2014, 08:15 AM

To solve my problem with the heat, I just got rid of the leg.

**cnc** · 03-30-2014, 08:40 AM

Yes how much smaller is the flange, perhaps you can open it up with a small grinder or dremel tool.

sly · 03-30-2014, 08:44 AM

Quote:

Originally Posted by Dave

To solve my problem with the heat, I just got rid of the leg.

That's drastique! Just get rid of the HD

just kidding, good luck with the fix

**ringadingh** · 03-30-2014, 08:53 AM

Quote:

Originally Posted by Dave

To solve my problem with the heat, I just got rid of the leg.

Thats a lot better than altering the bike....

**schoeney** · 03-30-2014, 09:28 AM

Quote:

Originally Posted by markclark57

I know a local plumber that could give you a helping hand on Monday.

Split ring escutcheon at Lowe's

Dave · 03-30-2014, 09:34 AM

Scott,

You do know that posting this, your just teeing it up easy for the Victory clowns!

**schoeney** · 03-30-2014, 09:36 AM

Quote:

Originally Posted by Dave

Scott,

You do know that posting this, your just teeing it up easy for the Victory clowns!

I don't think Brad and Kris would kick a guy while he is down....especially Scott.

**cnc** · 03-30-2014, 11:11 AM

Quote:

Originally Posted by schoeney

I don't think Brad and Kris would kick a guy while he is down....especially Scott.

Nope not their style, they'd wait till he got back up and trip him again.

**glwilson** · 03-30-2014, 11:17 AM

You would think you would do a little research to see if they fit before buying them...

Seriously though... what a PITA situation. Hope there is an easy fix for it, besides getting new pipes.

cactusjack · 03-30-2014, 11:27 AM

Here's the flange:

Here's the header pipe:

Here's the problem:

I don't have all day to dink around with this, in fact I shouldn't have had to mess with this at all. I really don't want to go grinding on chromed parts which will then rust. I am going to try heating the flange to 400° to see if it might expand enough to fit over the pipe. That's my last shot here. If that doesn't work, I guess I'll have to reinstall my old system and let V&H deal with this.

cactusjack · 03-30-2014, 11:29 AM

Quote:

Originally Posted by Dave

Scott,

You do know that posting this, your just teeing it up easy for the Victory clowns!

I don't see this as a "Harley problem". It's a V&H problem.

03-30-2014, 12:39 AM	#1
cactusjack Mega-Contributor Join Date: Sep 2007 Location: Where it doesn't snow...ever! Posts: 21,926	Arrrgh! Since AZ did away with mandatory motorcycle emission testing last year, I decided to replace my stock header pipes to get rid of the catalytic convertor that cooks the back of my right leg. I ordered a set of V&H Power Duals from Fuel Moto and Fedex delivered them yesterday. So i started replacing them this morning. I removed the stock exhaust and then did some detailing with the pipes off as it allows me to get to areas that are nearly impossible to clean with the pipes on. Then I installed the heat shields on the header pipes. I got to the step in the instructions where you slip the exhaust flanges over the new pipes and one of pipes is too large for the flange. They aren't split flanges like on a Kawasaki, they slip over and then you install a circlip which keeps the flange from coming off the end. So now I am stuck. I need my bike this week because I have a training class in downtown Phoenix and if I ride the bike I can use about 27 miles of HOV lane, and it is much faster and better than driving my truck. I will probably have to reinstall my stock exhaust tomorrow and then take up the issue with V&H on Monday. They are probably going to have to send me a new header assembly, because I don't have a magic flange stretcher. __________________ Scott "Cactusjack" Hanks VBA #00105 H.O.G. #4250060 2011 H-D Ultra Limited 103ci :: 2011 HD Electra Glide Ultra Limited w/Stage 1 :: Rallies: Mesquite '08\|Custer '09\|Cortez '10\|Crescent City '11\|Kanab '12\|Antlers '12\|Estes Park '13\|Antlers '13\|Orofino '14\|The Dalles '17 Login or Register to Remove Ads
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03-30-2014, 01:29 AM	#2
markclark57 Join Date: Jun 2010 Location: Phoenix, AZ Posts: 3,108	I know a local plumber that could give you a helping hand on Monday. __________________ 2006 Vulcan 1600 Classic "George III" (Patricia's) 2006 Vulcan 1600 Nomad "Grace" (Mark's) Mark Clark VBA #1619 TaibhseDaid@Gmail.Com "Irish" @ Maricopa County Chapter of B.A.C.A. Phoenix, AZ
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03-30-2014, 05:54 AM	#3
Loafer Sr. Contributor Join Date: Dec 2008 Posts: 18,287	Now that is a great idea!! Way to go Mark! __________________ Gerry Martineau / 802 VT / VBA #0892 /[email]glmjgm@gmail.com[email]
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03-30-2014, 08:11 AM	#4
dshelly Sr. Member Join Date: Mar 2012 Location: Belgrade, MT Posts: 2,824	Can you post a pic Scott? How much too small is the flange? __________________ Dave "(dshelly)" Shellenberger 2014 Harley Ultra Classic 2007 1600 Nomad (Black) Shellenberger Machine Belgrade, MT Various Bagger Member (Harley Chapter) VBA # 2395
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03-30-2014, 08:15 AM	#5
Dave Sr. Member Join Date: Dec 2007 Location: Itchycoo Park Posts: 3,422	To solve my problem with the heat, I just got rid of the leg. Login or Register to Remove Ads
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03-30-2014, 08:40 AM	#6
cnc Join Date: May 2009 Location: Montreal QC Posts: 12,034	Yes how much smaller is the flange, perhaps you can open it up with a small grinder or dremel tool. __________________ Norm Ward 2008 blue / silver nomad kawanow / VBA #01136
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03-30-2014, 09:34 AM	#10
Dave Sr. Member Join Date: Dec 2007 Location: Itchycoo Park Posts: 3,422	Scott, You do know that posting this, your just teeing it up easy for the Victory clowns!
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03-30-2014, 11:17 AM	#13
glwilson Join Date: Jul 2008 Location: North Central Illinois Posts: 8,575	You would think you would do a little research to see if they fit before buying them... Seriously though... what a PITA situation. Hope there is an easy fix for it, besides getting new pipes. __________________ "During times of universal deceit, telling the truth becomes a revolutionary act." "You can have your own opinion, but not your own facts." *Former VBA NCR Assist Regional Leader* Formerly: 2004 1500FI Bronze Nomad: 2009 & 2014 HD Ultra Current Rides: 2017 HD Ultra Limited & 2011 Can Am Spyder RTS-SE Attended: VBA National Rallies 2009, 2011, 2015; VBA/NCR Regional Rally 2010, 12, 14, 16 and several rides throughout with regional members. VBA Member #652 HOG Member #3935417
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03-30-2014, 11:27 AM	#14
cactusjack Mega-Contributor Join Date: Sep 2007 Location: Where it doesn't snow...ever! Posts: 21,926	Here's the flange: Here's the header pipe: Here's the problem: I don't have all day to dink around with this, in fact I shouldn't have had to mess with this at all. I really don't want to go grinding on chromed parts which will then rust. I am going to try heating the flange to 400° to see if it might expand enough to fit over the pipe. That's my last shot here. If that doesn't work, I guess I'll have to reinstall my old system and let V&H deal with this. __________________ Scott "Cactusjack" Hanks VBA #00105 H.O.G. #4250060 2011 H-D Ultra Limited 103ci :: 2011 HD Electra Glide Ultra Limited w/Stage 1 :: Rallies: Mesquite '08\|Custer '09\|Cortez '10\|Crescent City '11\|Kanab '12\|Antlers '12\|Estes Park '13\|Antlers '13\|Orofino '14\|The Dalles '17
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