Khromewerks 2-1 Problem
Thread Starter
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Intermediate
Joined: Mar 2024
Posts: 47
Likes: 21
From: Pittsburgh, PA
Khromewerks 2-1 Problem
In order to install a Thundermax, needed to change exhaust so I had 18mm ports for the Wideband sensors. After a bunch of reading and discussion, ordered a Khromewerks 200780 2-1.
It came in yesterday. Put today aside to do the exhaust and Thundermax install. Unfortunately, things not going well.
First of all, Khromewerks (who is obviously closed) shorted me the collector heat shield. Yes, I checked absolutely everywhere - even to the point of ripping the foam packing apart. No joy.
Second, following the instructions to the letter, there is zero way to get the muffler on. While there is a dimple for the axle nut area, it's ONLY at the axle nut area, and there is no friggin way this muffler is going on without beating it with a sledge and ruining the back of the muffler as well as gouging out the top with the axle nut and axle.
It's been a very discouraging day. I had hoped for better results, however the local shop I purchased the exhaust from is closed until Tuesday, Khromewerks is closed until Monday, and I have no way to proceed. Can't setup the Thundermax without the Wideband sensors. So, it appears as though Khromewerks has cost me at least a week, since I'm tied up next weekend - so probably two weeks.
Anybody install this setup on a '14 Ultra? I'm curious if I just have some quality issues with what I got in addition to the missing heat shield, or if there is some magical process. I did lightly lube the inside of the muffler inlet and the outside of the collector hoping that would maybe provide some relief, but nope.
It came in yesterday. Put today aside to do the exhaust and Thundermax install. Unfortunately, things not going well.
First of all, Khromewerks (who is obviously closed) shorted me the collector heat shield. Yes, I checked absolutely everywhere - even to the point of ripping the foam packing apart. No joy.
Second, following the instructions to the letter, there is zero way to get the muffler on. While there is a dimple for the axle nut area, it's ONLY at the axle nut area, and there is no friggin way this muffler is going on without beating it with a sledge and ruining the back of the muffler as well as gouging out the top with the axle nut and axle.
It's been a very discouraging day. I had hoped for better results, however the local shop I purchased the exhaust from is closed until Tuesday, Khromewerks is closed until Monday, and I have no way to proceed. Can't setup the Thundermax without the Wideband sensors. So, it appears as though Khromewerks has cost me at least a week, since I'm tied up next weekend - so probably two weeks.
Anybody install this setup on a '14 Ultra? I'm curious if I just have some quality issues with what I got in addition to the missing heat shield, or if there is some magical process. I did lightly lube the inside of the muffler inlet and the outside of the collector hoping that would maybe provide some relief, but nope.
Road Master
Joined: May 2008
Posts: 1,232
Likes: 428
From: Northern NY
I have a KW 2-1 Outlaw on my 2021 RGS. Get a tail pipe expander (Harbor Freight one works, the larger one) and expand the muffler inlet slightly. Also, if you have a die grinder, use a roll lock disk to put a slight bevel on the header where it goes into the muffler. Lube with some window cleaner. The Torca clamp on these call for quite a bit of torque. You will most likely have to use the expander again if you remove the muffler. It's a very small tweak, don't get crazy. I have run 2-1's for years, White Bro's, Fuel Moto, KW. They all can be a bit finicky to get the muffler on and off after use. Lube and twisting is your friend. Call KW about the missing shield, their customer service is great.
Thread Starter
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Intermediate
Joined: Mar 2024
Posts: 47
Likes: 21
From: Pittsburgh, PA
I have a KW 2-1 Outlaw on my 2021 RGS. Get a tail pipe expander (Harbor Freight one works, the larger one) and expand the muffler inlet slightly. Also, if you have a die grinder, use a roll lock disk to put a slight bevel on the header where it goes into the muffler. Lube with some window cleaner. The Torca clamp on these call for quite a bit of torque. You will most likely have to use the expander again if you remove the muffler. It's a very small tweak, don't get crazy. I have run 2-1's for years, White Bro's, Fuel Moto, KW. They all can be a bit finicky to get the muffler on and off after use. Lube and twisting is your friend. Call KW about the missing shield, their customer service is great.
Road Master
Joined: May 2008
Posts: 1,232
Likes: 428
From: Northern NY
thanks. However that doesnt solve the interference issue. The muffler is FAR too close to the axle assembly. Ive also installed tons of 2-1 exhaust systems. Fatcat, road rage, etc. And far more on my race bikes. Never had so many issues as on this one before. I have a call into khromewerks. Not proceeding now until I talk to them as Im convinced the muffler will get gouged all to hell. Theres not even enough room for a t shirt between the muffler and the axle nut. I thought about pulling the axle but dont want to get in a situation where the axle needs to come out to remove an exhaust.
Thread Starter
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Intermediate
Joined: Mar 2024
Posts: 47
Likes: 21
From: Pittsburgh, PA
Thread Starter
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Intermediate
Joined: Mar 2024
Posts: 47
Likes: 21
From: Pittsburgh, PA
But in this case, it just does not matter. If I had installed the muffler first, the only way I'd be able to get it on would be to really put a lot of torque on it - with two likely outcomes. First, I probably would have scratched the hell out of the muffler in the process because it's so close to interference against the axle, and second I would have distorted the exhaust gaskets.
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Road Master
Joined: May 2008
Posts: 1,232
Likes: 428
From: Northern NY
I appreciate the idea, however I do not agree with that at all. I'm not exaggerating - but I've probably installed at least 50 full exhausts on bikes. Actually probably a heck of a lot more. I have never, ever, in a single one put on the muffler before I had the entire header assembly secured and torqued. In particular when you're dealing with full titanium exhausts, you really don't want to screw around. Mistakes are VERY costly.
But in this case, it just does not matter. If I had installed the muffler first, the only way I'd be able to get it on would be to really put a lot of torque on it - with two likely outcomes. First, I probably would have scratched the hell out of the muffler in the process because it's so close to interference against the axle, and second I would have distorted the exhaust gaskets.
But in this case, it just does not matter. If I had installed the muffler first, the only way I'd be able to get it on would be to really put a lot of torque on it - with two likely outcomes. First, I probably would have scratched the hell out of the muffler in the process because it's so close to interference against the axle, and second I would have distorted the exhaust gaskets.
Khrome Werks has great customer service. They will take care of you.
Last edited by klammer76; Apr 14, 2024 at 11:02 PM.
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Thread Starter
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Intermediate
Joined: Mar 2024
Posts: 47
Likes: 21
From: Pittsburgh, PA
I have installed several also. KW, Fuel Moto instructions state to have the full system together then tighten starting at the front and working back. Again, I have done it both ways also but have better results after installing the header loosely then the muffler loosely then tightening. Not saying that will solve your problem and doubt it will. There have been reports of this same issue with the KW 2-1 in the past if using a longer 14" shock. The shocks on my bike are 13" as well as a friend with a RG ST and 13" shocks, no issue. The attached video at the 4:00 minute mark mentions the interference when using a longer shock. The installer is a very well known and knowledgeable guy (not the annoying one that talks a lot). What length Pro Action shocks are you running on your Ultra, 13" or 14"?
Khrome Werks has great customer service. They will take care of you.
Khrome Werks has great customer service. They will take care of you.
just for accuracy khromewerks does NOT say to have the full system together and then tighten from front to rear. I can upload the instructions if necessary. Their instructions explicitly state to install headers with front and rear exhaust flange nuts loose then p bracket at tranny cover loose then torque flange nuts and then p bracket. THEN install muffler with clamp.
however even then the root issue isnt addressed. Assuming I did it the way you suggest I do not believe that changes the root issue of interference.
Ive called them and left a msg on Saturday but will call them today. We will see. Im suspicious as I forgot to mention they supplied two different p brackets with different designs- though its not mentioned anywhere in parts list, instructions, etc. yes I tried both. Between this, the fact that I was shorted the collector heat shield, the clear interference, my concern is high.