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Help Installing V&H Power Duals on my 2015 Ultra Ltd . . .
A couple of questions about installing V&H Power Duals on my 2015 Ultra Limited:
Although the Power Duals kit came with 'crushable' exhaust gaskets, I couldn't find anything that looked like exhaust gaskets when I removed my OEM headers. What gives? Nothing fell out of (or into) the engine when I pulled the headers. The bike has about 900 miles on it. All I found was very smooth and suprisingly clean metal on intake manifold where the pipe fits. The pipe itself didn't have a gasket 'embeded' in it. No apparent leaks or discoloration. Do these headers just not need exhaust gaskets?
What can I do to more easily access the front exhaust port for the purpose of installing the header? Since this is a 'wet-head' with an active water cooled radiator, I'm a bit nervous about removing the lowers. Whats the best approach?
Any help or advice would be greatly appreciated.
Mark!
Last edited by markfsanderson; Sep 20, 2015 at 09:57 PM.
Reason: Adding the bikes year
In spite of the fact that the ports look like there's no gasket - there IS. They are cone shaped and need a pick or something to pull them out. I suggest you replace the stock ones rather than use the flat ones V&H gives you. OEM seals better.
Sounds like sage advice, I'll pick some up tomorrow at the dealership. Any advice on making access to the front exhaust port easier? What a PITA to get things to work right . . . Oh - and even though my bike has less than 1k mileage - I should still replace the exhaust gaskets?
When I put the PD's on my '15 Limited Low, I remember it was a struggle. For the longest while I swore they were welded wrong or something. Then.... they just went right in lol. Didn't have to touch the lowers.
You have to get the angle and all EXACTLY right. I seem to recall you have to put the front pipe in the head first & kinda swing the rest around into place. Also the instructions made the whole thing way more complicated than it is.
One tip...
They go on a lot easier if you have the flanges right up to the ends of the pipes. If you try to put the pipes on first then slide the flanges up they don't want to clear. I used plastic zip ties to keep them from sliding down. The kind with the little lever that you push to release them, and just pull them right out when done.
There is also a tightening sequence for the header nuts, like top just snug, then bottom tight, then top tight or something like that.... it's in the manual.
They are a REALLY tight fit, tape stuff up with that blue painter's tape & don't be in a hurry.
Good luck!
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Bikerscum - I'm not familiar with those kind of zip ties, they have a handle? Where can I find these at? Using removable zip ties is a great idea, just not sure where to find them. I'll retry the install using your approach. The interesting part about the instructions is that they want me to remove the headers after an initial fitting, tighten some fasteners and re-hang and then tighten the headers. The way its going now, if I get it on there once - It's going nowhere! What a pain!
p51bombay - Thanks! I've got a pick - I'll start digging . . . and I'll purchase the OEM gaskets today . . .
Oh and to add to the joy . . . I lost a header pipe nut in the transmission while uninstalling the original . . . I guess I'll pick up a couple at the dealership. Wish me luck - and keep the advice coming!
Mark, the zip ties just have a little tiny tab right at the "buckle" that you push in to release, maybe most of them have it I don't know. I just know they all don't. I think I got mine at home depot. You can use any kind really but with out the release tab you'll have to use a razor blade or something & cut them off.
If you haven't already taken the stock gaskets out, look them over and if they're in real good shape, I would consider using them if they have less than 1k on 'em. Putting new ones in is kind of a pain (they're fairly delicate) without the tool and if you didn't damage them taking the stock headpipe out, it might save you some frustration.
The V&H Power Duals use a flat gasket not the coned stock style. Look at the head end of the stock header pipe and the end of the V&H and you'll see why. Harley does have a Screamin Eagle exhaust gasket that is flat like the V&H if you want to have a spare on hand. I've put on several sets of Dresser Duals and a couple Power Duals using the V&H gaskets and never had a problem or leak. V&H has good instructions and I'll attach the tightening sequence from the HD manual.
This probably doesn't need to be mentioned but just in case: the exhaust flange torque is in INCH pounds. and you should check it again after a few rides
Some have found that a washer will ensure you don't run down to the end of the threads, so if you find it still leaks a little try a washer on the nuts.
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Help Installing V&H Power Duals on my 2015 Ultra Ltd . . .
Painters tape and zip ties . . .
