I've got a 1996 FLHRI 7000 mi, completely stock. Looking to free up the exhaust and increase the airflow. Need recommendations from veteren Harley owners. Please be specific and brand names (Vance & Hines, etc) will help me determine which way to go. I want increased performance. I'm new to the adventure. Thanks.

 

assuming it is fuel injected because of the "I" at end of model number.
There are so many possibles impossible so say which you will like best.
but basically check different manufacturers websites to see what they offer for your bike. (J&Pcycles, dennis kirk, vance and hines, samsonusa,arlen ness). J&P and Dennis kirk will send you a catalog (easier than web searches). Power commander. to name a few.
HD makes stuff too.
But a lot depends on how much you got to spend and are you going to do it in steps or all at once?
but to start
1. full flow aircleaner with a fuel management device
stage 1 download from HD (non tuneable)
SERT from HD very tuneable about $400
Power commander tuneable about $280 and up
2. Aftermarket pipes to fit your fancy and pocket book
Retune may be needed
3. mufflers (same as pipes)
You need to go listen to some mufflers to hear a sound
you like (loud soft etc)
What gives good torque and HP on one guys setup may not be same as
on yours and your riding style.
Go out and ride your bike and find out at what RPM do you find yourself at for most of your riding (gear does not matter)
I find gentle cruising in 3rd, 4th and 5th I am normally around 1800 to 2800 rpm so I tuned mine to kick in, in that range and carry through till about 5k. Rarely do I get above 4200rpm.
I find 5th gear 90 mph I am right at 3800 rpm, but rarely drive that fast.
Hope this will give you a guide line.
When you start tuning the bike, remember tune optimum hp and torque
as close to the actual RPM's you will realistically be driving at.
mines an 06 Electraglide classic for daily running.
also have an 01 EG both are setup same.

 

Stage 1 - Exhaust - Air - Fuel Management system for starters

 

In addition to the sound advice above, stay away from "open" drag pipes. While they may produce the loud sound that appeals to many, they rob performance and torque. I took a set of 2 1/4 inch straight pipes off of my EVO (96 Heritage) and put on a set of Pythons with the hidden crossover and it made a significant increase in the bottom end and overall. This translated to increased acceleration and a higher top end than with the straight pipes. A very good thing. As for me I added a Screaming Eagle air cleaner to help with the intake side of things. It is comparable to the K&N filter which is cleanble and reusable, money well spent.
Of course if power is the quest, increased compression (10.1 pistons) and increased bore (.10 over)are options. One thing leads to another......Heads flowed and ported, bigger carb if applicable and so and so on. It all depends on how much money you are willing to throw at it. Have fun!

 

SE Air cleaner, good pipes, ie. HD Touring mufflers, Vance and Hines, Rienhart, SuperTrapp, etc.rejet carb if it has one, get a tuner if not, and replace the cam with an Andrews EV13. Replace the caged cam bearing that has a tendency to fail with a Torrington roller bearing when you change the cam.

Bill

 

You're gonna find that the '96 is a little hard to modify, if you haven't figured this out yet. Virtually everything on the market (except pipes) says "'99 and later". So be careful and ask lots of questions. I recently found a wrench who had an H-D catalog that listed a fuel tuner that works on my '96 UC. It appears to bea V&H Fuel Pak rebranded with SE badging. I've been looking for this for over two years. Here's a little rundown on what I'll be starting on next week:
SE Fuel Pack lists for $228 in the catalog
SE-3 cam
Heads will be ported and polished
New rear base gasket due to seepage
SE Air Cleaner (may do Ness Big Sucker instead)
New cam bearing
New lifters
Adjustable pushrods
Samson Rolled Thunder slipons (these have been on the bike for several years already)
Take a look at www.hildrethperformance.com John's doing my work and can put together a package of recommendations for you.

 

..carbed or FI Twin Cam?..tons of stuff available for carbed Evos..
Later

 

My last bike was a '96 RK (carb), and I rode it for nine years and 106k miles. It was very restricted out of the box, and needed mufflers, carb mods (EFI for you), a mild cam, and aftermarket ignition module. I settled on Samson Rolled Thunder, which were a bit noisier than I might prefer, but any free-flowing slip-on would be an improvement over stock. Can't help with the best EFI mod, as I'm using PCIII on my '07 SG and they don't list anything earlier than '99 on the PC site. I do know that Stage 1 will kill your gas mileage, so you might want to look elsewhere.

An aftermarket cam is a must on an Evo, IMO. I selected the Andrews EV13, a low- and mid-range touring cam that gave excellent power from 2500-6000 rpm. Below that was a bit weak because of the low compression ratio (8.5:1), and upping it to 9.5:1 would be beneficial. I left mine at stock CR, which was fine. An aftermarket ignition module is also a must, IMO, and I went with the Crane HI-E4 with single-fire coils.

Do all this and it will wake-up that old Evo without costing you an arm and a leg.

 

Chances are that your cylinders are out of round by now, not an uncommon issue with the EVO lumps. I'd worry less about what pipes vs. getting the engine in tip top shape.

* MTC .010 over-size piston kit, cleans up and trues up the cylinders, slight bump in compression.
* 3-angle valve job with new valve guides and seals, have the bowls blended and get the exhaust and intake ports cleaned up as well.
* EV23 or EV27 cam
* V&H, Bub, etc. full exhaust of your choice
* Filter kit & EFI remap