Need a little help. I'm putting Cycle Shack Turnouts on my 05 1200C this weekend and was wondering if anyone has the instructions. I want to make sure I don't damage the gaskets. Thanks

 

If you are doing the slip ons I would invest the few dollars it costs for the two gaskets that connect the slip ons to the crossover...just to be on the safe side and not have leaks. Have done several of these for other folks and always changed the gaskets so I would not have to "re-do" because of a leaky conneciton. If you need the part number it is 65927-00...you get two in the pack.

 

Thanks much appreciated.

 

Wviceman: I put the same system on my XL1200R just a few months ago. Buy those two little gaskets before you begin. It worked best for me to loosen everything and take the heat shields off totally. This is a good time to remove the header pipes from the cylinders and see that everything is "OK" there. Start re installation with the front header and reinstall with gently snugged nuts/bolts but do not torque them down until later. Put on the muffler for that header pipe. Put the crossover pipe into place without its fastener and set it into the front muffler. Again set the fastener clamp down but not torqued yet. Install the rear header pipe and install the rear muffler. Bring the crossover pipe into play while mating it with the new rear muffler using the new gasket. Again just snug up the mounting bolt and the header clamp. Set the whole assembly of both pipes, mufflers and crossover pipe where they look "right". Then start with the header nuts to the cylinder and work your way to the rear while tightening up everything. When you are satisfied that everything is in alignment torque down all fasteners. Then put the heat shields back on and tighten them. I used just a dab of "Blue Locktite" on everything except the nuts to the cylinders. I don't remember my reasoning now, but they are easily accessible with the right socket or wrench and can be checked later and often. After four or five rides with the new system go back and check all fasteners for tightness.

Before you take anything off, note where the clamps are oriented originally. You may want to alter the factory clamp location slightly, but generally speaking the factory position is about optimum. Be sure and clean the fingerprint oil off all chrome surfaces with Windex With Ammonia before starting up the first time. If you don't the stain can be permanent. Remembering back, I also removed the A/C Shield and air cleaner element just to prevent me from hitting the Shield with a wrench.

Be sure to box up and save your original mufflers. Someday soon we might be forced to put them back on to pass the EPA's inspection.

My CS Turnouts are a little loud, but are quiet enough if I am not hard on the throttle. You will enjoy them! Be sure and rejet your Carb as required. ................... BC

 

Big Cholla,

That was a world of good advice much appreciated. I've never on a bike but plenty of cars, just don't want to make any mistakes with my baby.

 

I put turnouts on mine. Instructions come with the new mufflers but here's the short version:

The dealer will have the exhaust gaskets in stock. They do muffler swaps all the time so little chance they won't have any on hand. They run about $8 for a set of SE gaskets or $5 (each) for stock ones. I have no idea why the stock ones cost more or what the improvement is on the SE set. I was real careful getting mine off and only had about 300 miles on them so I reused OEM gaskets. But $8 is an inexpensive piece of mind. You can always take them back if you don't need them.

Loosen clamps on heat shields - standard hose clamps. I think its 2 per pipe. The instructions will tell you to remove the heat shields. Your call. I don't think I really needed to.

Loosen clamp between muffler and exhaust pipe, one each. Slide it forward off the muffler and onto the exhaust pipe out of the way.

Remove 2 bolts under each muffler. These attach muffler to crossover tube.

At this point you should be able to wiggle the mufflers off.*** Look underneath the mufflers forward of those 2 bolts you took off. You'll see the quarter sized coupling where those gaskets are located. Careful not to smash them when pulling the mufflers free (if you plan to reuse them).

Install is pretty much in reverse.

***Some people said it was a bear to get the old mufflers off. Mine weren't too bad. I used a big bladed, flat tip screw driver and a hammer and carefully tapped on the edge of the muffler to break the seal. Then I held the screw driver in the expansion slot and twisted a bit to open it up. I also loosened the exhaust pipe mount bolt on the rear pipe. The exhaust pipe/head mounting has a little play in it to allow you to pull the mufflers off the crossover tube and then wiggle them off. Its slow and methodical. I took about 2-3 minutes (max) per muffler. I wiggled north, south, north, south, etc......then east, west, east, west.......while pulling toward the rear of the bike. It feels like nothing is happening at first but then you'll see them slowly start to come off.

I read some stories about difficulty getting the old ones off; some said over 2 hours of banging and pulling. But the whole install took me MAYBE 30 minutes start to finish. And that includes the time it took me to polish and box up the old mufflers.

Oh yeah, make sure you pull out the crumpled newspaper from inside the pipes before firing up your ride. I didn’t see it right away.

This is an easy install. Instructions with the mufflers and this will be more than enough to get it done. It'll all make sense once you're hands-on. If you need it, the service manual also describes muffler removal on pages 2-104 to 2-106.

Good luck. Don't forget the last step....post pics and let us know how they sound.

EDIT: Didn't see Big Cholla's post. Unlike him, I didn't pull the header pipes off. Like I said, I only had about 300 miles on the bike so I wasn't too concerned about internal engine problems. Figured it was too new to tell anything anyway.

 

Good posts by Big Cholla and bensonjv! Everything you need to know (and more) is right there, but PM me if you need the instructions - I can fax 'em, or scan 'em, and send 'em to ya.

I couldn't pull or wiggle off the rear muffler at first. I didn't have any WD-40 around at the time, so I used Pam cooking spray - let it soak in at the joint for a few minutes and it came right off. In all, took me about 45 minutes (including the cooking spray soak!).

6700+ miles on the CS slipons and I still love 'em.

Good luck!

 

What a GREAT bunch of Enthuisust's!