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Sportster Motorcycle Air intake, Carburetor, EFI, Fuel, and Exhaust Problems, advice and/or how tos for Sporster and Buell motorcycle carburators, Electronic Fuel Injection (EFI), Air Intake, Fuel and Exhaust.

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  #1  
Old 16th June 2018
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Default Aligning ‘14-newer OEM exhaust?

I have a ‘15 XL1200CP. I’m replacing the stock chrome baloney-cut mufflers with black tapered OEM takeoffs. The chrome mufflers came off easily enough. When I installed the new mufflers, getting all the mounting holes to align was really difficult. Given that the exhaust has to be removed to check the rear engine mount (10k/yearly?), I’m considering wobbling out the mounting holes on the muffler-support bracket to make everything fit easier.

Question: Is there a trick or a special sequence that I’m missing?

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Old 17th June 2018
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Didn't have any trouble when I did mine; maybe I was just lucky?
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Old 21st June 2018
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Default

Quote:
Originally Posted by Folkie View Post
Didn't have any trouble when I did mine; maybe I was just lucky?
Maybe just smarter? My mistake was tightening the exhaust-flange nuts before the mufflers were loosely installed.

This worked:
- Installed the exhaust manifold with the exhaust-flange nuts finger tight
- Installed the muffler bracket on the front muffler with the bolts loose
- Installed the front muffler with the muffler clamp loose
- Installed the rear muffler with the bolts and clamp loose
- Tightened the exhaust flange nuts first (90-120 in-lbs!)
- Then, per the manual, tightened in sequence:
— The muffler mounting-bracket bolts
— The muffler-to-bracket bolts
— The muffler clamps

Easy peasy when you do it by the book!
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