Is this the stuff you guys are referring to?

 

Hey tonygret, I am also in California and one of the big considerations I had for even choosing slipons was because they would SLIP OFF!! Lots of my friends are getting ticketed, especially in the coastal cities. They just put their old stockers back on, go down to the police station and get their fix it ticket signed off.

I'm thinking maybe that copper goup will make that project alot more difficult to do....something to think about.....

 

yes that is exactly it, and when you put it on, don't fire up your bike for a good 12 hours, so it can set in place.

 

OK. I got the sealant and reinstalled the mufflers tonight. I'll let it set up overnight. They came off al lot easier than I thought. I did notice that after tightening the muffler clasmps the mufflers found their own orentation on the header pipes. However when I went to tighten down the bracket, it pulls the rear muffler down a bit. So I left the bracket loose for the night and will tighten it tomorrow. Does anyone think i should have tightened it tonight and let it set up the way it was going to be?

Followup tomorrow . . .

It's tomorrow.

So I started it up today and there is still a very slight exhaust leak. Like babies breath, but it's there. Am I going to have problem with this leak? And now that I have the sealer in there, how hard are these going to be to take off if I need to do this again?

 

It's tomorrow.

So I started it up today and there is still a very slight exhaust leak. Like babies breath, but it's there. Am I going to have problem with this leak? And now that I have the sealer in there, how hard are these going to be to take off if I need to do this again?

 

I think you made a mistake by letting the Permatex harden before tightening the bracket bolts, seeing as how tightening the bracket bolts moves the rear muffler. You may have to rotate the mufflers slightly or shim the bracket with washers (I had to use washers on mine) to get everything aligned, but you need to get it so tightening the bracket bolts doesn't put the mufflers in a bind. Snug all the bolts gradually, wiggling the mufflers as you go, to make sure everything is lined up.
My Rush mufflers fit real loose over the header pipes; the inside diameter of the mufflers was quite a bit bigger than the outside diameter of the pipes. Make sure your band clamps are only over the slots in the muffler inlets, no part of the clamp should be over the solid part of the muffler inlet. You may have to slide the band clamps toward the right (front of the bike) far enough so there is some slot visible on the left (rear of bike) side of the clamps. If you try to tighten the band clamps over the solid part, you won't compress the muffler inlet and you won't get a good seal. You might even lose your mufflers.
Anti-seize on the band clamp bolts is a good idea. They tend to gall if you repeatedly loosen and tighten them.

 

murphdog makes a very good point if you hadn't allready then check to make sure your clamps are towards the ends, what you really want is to tighten down around where the slits are, the clamp has the most effect there, if it's tightened down closer to the muffler itself, it's not really tightening down a lot. So check that out. I've got an 06 streetbob and I just bought and installed a month ago the rush 1.75's same as you. Mine out of the box were too tight to get on the headpipes, I had to spread them right at the splits on the end just slightly to go over the head pipes. Some guys swear by the permatex sealant other guys never use it. I ran my screaming eagle slip ons for about a year, and I had them suckers off and on and off an on so many times trying to get it to not leak at the slipon connection. So when I bought he rush muffs I researched where a bunch of folks suggested permatex on the flanges, so I decided to try a light film, and I don't notice the leaks.
As far as it coming off, well, haven't tried it personally but that's why I mentioned a light film because it can't be any more difficult than trying to get them suckers that are rusted/welded on there off, at least the sealant won't rust.

One other thing, if you wanted to redo it, I would have (and did myself)
1. Loosen clamp bolts and bracket bolts...
2. I actually removed heat shields and headpipes to put in new gaskets but more importantly wanted to verify torque at exhaust ports were torqued to spec.
3. After torquing exhaut port nuts, slight film of permatex appied to slip on flange, then put slip ons on and wiggled them around to a nice neutral position.
4. Applied a thin film of antiseize to band clamp bolts,halfmoons, and then loosely installed clamps on bolth slip ons and loosely installed connecting bracket and bolts loosely.
5. While tightening up both upper and lower slip on band clamps, verified 1/4 inch gap minimum between both slip ons.
6. Tightened down slip on band clamps, with some meat behind it, I torqued upper exhaust port nuts but no I don't torque band clamps, just good and tight.
7. Tried to move and pull on slip ons to make sure they can't rotate or pull off at this point. This is with the bracket bolts loose because the bracket bolts aren't there to keep the slip ons tight on the head pipe, I believe the bracket bolts are more for keeping the two mufflers together and they each give each other some support plus if you have the bracket bolts on right you should be able to maintain the 1/8 to 1/4 inch gap between the two slip ons.
8. Now I would tighten down bracket bolts
9. Let sit over night to dry, if you fire up immediately after, you defeat the purpose of the sealant by blowing it out.

One other thing, after a hundred miles, I rechecked my torque on my exhaust port nuts and made sure band clamp bolts were still good and tight.

 

In case it's already been said +2 for new clamps.

HD says the clamps are use once and throw away. They stretch and the second (or third) time you try to reuse them they will tighten all the way down but will not be snug/tight around the slip-on.

8 bux from HD - I keep an extra in the tool box.
George

 

Thank you all so much. I just put 100 miles on it. I stopped twice and when it's hot I don't feel any leaks. I let it cool completely down and started it again, the very slight leak is there. I don't see any signs of black soot on the header pipes. I think at this point I will take a "lets see what happens" approach.

On another note, there is no decel poping from the new mufflers and I don't hear any strange noise that can be attributed to a leak. The Rush 1.75's are exactly what I was looking for. I had some V&H on my 06 ultra and it was so loud it bothered me on long rides. I think this is a perfect trade off of between "deafining" and "stock".

 

Is that a 400 pound *** on a 4-legged ***? Or is it a 400 pound *** on a 2-legged hog?

Regarding the exhaust, you shouldn't need sealant of any kind. Reusing the exhaust clamps at the low mileage you have should be fine. Make sure everything is lined up, make sure that the mufflers are all the way on and seated, and that the clamps are positioned correctly and tightened to specification. There should be no leaks.