Exhausted....
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Elite HDF Member
Joined: Oct 2005
Posts: 3,872
Likes: 83
From: Canton, Michigan
Ordered a Thunderheader today. Should get it by Wednesday next week. New gaskets, etc. on the way too. Although I really like the look of the dual exhaust, I can't justify the cost of replacing the existing system. My SuperTrapp slip-ons are in need of replacing too, so if I went the OEM route, I'd be better off converting to the 1995 and up system. Putting used parts on, isn't something I'm willing to do right now.
Unfortunately it's 29* and snowing outside...
Unfortunately it's 29* and snowing outside...
Last edited by Hackd; Mar 2, 2017 at 10:58 PM.
Thread Starter
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Elite HDF Member
Joined: Oct 2005
Posts: 3,872
Likes: 83
From: Canton, Michigan
Thunderheader came today, so I started the install. The directions leave a lot to be desired.... But it just an exhaust, so it's pretty elementary.
Anyway, the stock lower exhaust bracket that's attached to the transmission needs to be removed/replaced so the Thunderheader bracket will bolt on. Had to pull the side cover (and I just did an oil change on the transmission...). The lower most bolt hole is stripped. I have no idea how it got stripped, as I've never removed it (owned since new), and I don't recall any of the various shops that have touched my bike in the past 23 years working on that area of the bike. But it's stripped out. I mean, the bolt slides easily in/out stripped.
Going to get a Helicoil and try to repair it. Anyone have good/bad experiences using them?
Anyway, the stock lower exhaust bracket that's attached to the transmission needs to be removed/replaced so the Thunderheader bracket will bolt on. Had to pull the side cover (and I just did an oil change on the transmission...). The lower most bolt hole is stripped. I have no idea how it got stripped, as I've never removed it (owned since new), and I don't recall any of the various shops that have touched my bike in the past 23 years working on that area of the bike. But it's stripped out. I mean, the bolt slides easily in/out stripped.
Going to get a Helicoil and try to repair it. Anyone have good/bad experiences using them?
Thread Starter
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Elite HDF Member
Joined: Oct 2005
Posts: 3,872
Likes: 83
From: Canton, Michigan
I ordered a kit off Amazon, should be here Friday. That'll give me time to get gaskets for the transmission side cover and the oil spout casting.
I've never used them, so I guess it'll be another learning experience.
I've never used them, so I guess it'll be another learning experience.
Club Member
Joined: Aug 2008
Posts: 22,861
Likes: 17,918
From: Lafayette, Louisiana
Helicoil can be bought at autozone, O'Reilly etc.
They work good for normal stuff.
I used to work at O'Reilly's btw.
They work good for normal stuff.
I used to work at O'Reilly's btw.
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Thread Starter
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Elite HDF Member
Joined: Oct 2005
Posts: 3,872
Likes: 83
From: Canton, Michigan
Thanks, maybe I'll swing by there today (I've got O'Reily's, Autozone, and NAPA close). Fastenal didn't have the kits, but could assemble one for me, but it was going to be a lot more than Amazon.
Any 'tricks' to installing them? Threadlocker?
Any 'tricks' to installing them? Threadlocker?
Seasoned HDF Member
Joined: Jul 2011
Posts: 27,097
Likes: 4,676
From: Frozelandia, Minnysota
Take it easy with the tap, if it feels like it's binding, back off a bit then go back down, repeat as necessary, might even take it out a couple times and clean the shavings off. Sometimes a little oil helps. I don't think I've ever used threadlocker - locktite - they stay in pretty good. The helicoil should go in easy once the hole is tapped, you don't want to break the tang off at the bottom. I've done many of them, don't get in a hurry, shouldn't be a problem.