| Author | Message | ||
     Cpilot |
Was getting ready to start to install the right-side air scoop of the Comfort Kit, when I looked at the muffler to header joint and it seemed to be leaking. I removed my exhaust wrap to get a better look. Looked like quite a bit of leak. Since I had a new front strap in hand I thought I would remove and take a closer look. The muffler to header joint is barley connected. It looks like the muffler has slid onto the header about 1/16 of an inch or less. I loosened the rear clamps to see if I could work it on a little farther. No luck. Question, how far should the exhaust header slide into the muffler? I was hoping to do a ride tomorrow but it looks like this may have thrown a wrench into the works. Any suggestions would be appreciated. | ||
| Ratbuell |
There should be a flare; it should fill the flare IIRC. About 1/2" or 3/4". When you install, use some UltraCopper RTV to seal the gap. Put a bead on the inner pipe and slide the outer one over it, then clamp. Don't be afraid to brace a 2x4 against the back of the muffler, and give it a couple love-taps with a hammer to slide the muffler forward  | ||
| Cpilot |
Ratbuell, I'll give that a shot in the morning. But it looks like the muffler is all the way up contacting the front strap bracket. It doesn't look like it will go any higher, certainly it won't let the header slip into it a 1/2 to 3/4 inch. I'll check to see if sliding the muffler forward will give it some more room. Thanks.... | ||
| Xbimmer |
Is the bolt that holds the front muffler bracket to the engine broken or missing? | ||
| Cpilot |
I have loosened the rear straps and have moved the muffler a number of different ways, but still can't get it to slip over the header. I am going to try to attach a couple of pictures.    | ||
| Cpilot |
The bolt that attaches the front muffler strap is there, I have loosened it so see if if the bracket had any up and down play to give me more clearance to slip on the muffler, but it doesn't have any play. | ||
| Hughlysses |
What do the rear straps and mount look like? If the muffler is where it's supposed to be and the header joint doesn't fit, maybe the header isn't where it's supposed to be. Check front and rear header-to-head joints. (???) | ||
| Cpilot |
The front and rear header-to-head looks ok. The rear straps look to be in the proper position. I think I'll need to contact the local dealer who had the exhaust off to do my kick stand replacement and repair. | ||
| Ratbuell |
I agree. Loosen your head flange bolts, adjust header (looks like it needs to rotate - at the collector - towards the left side of the bike), fit muffler. Snug everything so it doesn't slip apart. Then, tighten from the heads down to the rear of the muffler. Everything should stay in alignment at that point. | ||
| Xbimmer |
I think I'll need to contact the local dealer who had the exhaust off to do my kick stand replacement and repair. Well there's your problem most likely... I don't know whether it would make much of a difference, but it looks like your muffler is rolled too far to the left, the front bracket is sitting on top of the right side chin fairing bracket where it's welded to the muffler. Or looks like it to me in the first pic.  | ||
| Teeps |
I measured the witness marks in my stock muffler and they are about 7/8" deep. You might want to open the inlet tube a little. This may ease the fitment between the muffler and header; a flat blade screwdriver works for doing this. Also,I use aluminum based anti-seize to lubricate the connection. The critical thing to keep in mind is there should not be any preload on the headers when the muffler is fitted. That is the engine, headers and muffler must be one monolithic structure when correctly installed. Anything less can result in broken muffler straps, cracked header pipes or broken exhaust flange studs. | ||
| Cpilot |
Since I still have some warranty left, and since it was the last warranty repair is probably what precipitated this condition, I'll give the dealer a call tomorrow. I think the idea of start with a top down would be the next thing to try. Good reminder to that there should be no binding as it goes to together. Thanks for all your information. This web is amazing. I'll let you know what I find out. | ||
| F_skinner |
Cpilot, if you are using PPHD there is half your problem. I would take it up to HCHD. It is out of the way but it is worth it to have Buell Enthusiast work on your bike. | ||
| Cpilot |
F_skinner, I hear you... I wish they were closer. I really like the guys up at HCHD. | ||
| Jlnance |
Learn from my mistakes. Make sure you replace the front muffler strap with a new one each time you take the muffler off. | ||
| Cpilot |
Just an update... the dealer called Buell. It seems that there have been cases where the header has been cut off too short at the factory, causing to not have enough length to properly slip in to the muffler. So Buell has authorized to replace the headers. I could have been living with only 1/16 slip joint all along and didn't know it. Or something has moved on the header, and the disassemble should show it. |
