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Buell Motorcycle Forum » XBoard » Archive through March 28, 2010 » Cracked header on 08 lightning « Previous Next »

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Ghost_rider33
Posted on Tuesday, March 23, 2010 - 12:02 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I have a k&n air filter and D&D muffler on the lightning. The header has cracked three different times. The dealership is replacing the header under warranty, but they want me to pay 600 dollars to dyno tune it. They told me that my bike was running way too lean. Would the EBR ecm fix this lean condition? I have a hard time believing that my bike is running hot enough to crack the header. I may be wrong though.
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Froggy
Posted on Tuesday, March 23, 2010 - 12:12 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Where is it cracking? It is more likely due to poor installation of the muffler or improperly torqued header bolts.
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Ghost_rider33
Posted on Tuesday, March 23, 2010 - 01:08 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

It cracked at the collector twice, and in the tight bend of the front pipe.
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Joel9
Posted on Tuesday, March 23, 2010 - 01:32 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

in your profile you say that you have wrapped headers. could this be the problem?
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Glitch
Posted on Tuesday, March 23, 2010 - 07:05 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Wrapped headers won't crack them.
Something else is amiss.
With regards to the EBR ECM, aren't they tuned for racing?
If they are (I think they are) it may not do so well on the street, being tuned for the upper RPM range.
$600 for a dyno tune doesn't sound too far off the norm.
However, I doubt you'd need it, just re-flash the ECM with the correct map.
Did they check the intake for leaks, that would cause a lean condition.
Any air box mods?
We took apart Shred's bike, he had a free flow muffler, and drilled air box, the rear cylinder's exhaust valve was extremely white (way lean), haven't check the front yet.
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Ghost_rider33
Posted on Wednesday, March 24, 2010 - 01:36 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

I don't believe they checked the intake for leaks. They didn't mention it. The air box is completely stock. Where would I be able to find the maps for an 08? And how would I re-map the ecm? Maybe EBR would be able to do a more street friendly map?
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Jason13
Posted on Wednesday, March 24, 2010 - 03:19 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

mine cracked also but it was bc of the bolt was loose that goes from the block to the d&d. you couldnt tell it was loose tille i put a socket on it.
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Ghost_rider33
Posted on Wednesday, March 24, 2010 - 11:45 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only)

Mine got loose too, but I tightened it up as soon as I noticed it. No telling how long it was loose. I noticed it while changing the oil. The header cracked once before the D&D and K&N. I had to get it welded because I was pretty far from home. I'm just glad that HD is fixing it for me under warranty.
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