Yeah, you'll be alright with your black pipes but in my case, I'd rather be safe than sorry.

 

Got the dresser duals on with no leaks at the cylinders. I was really worried about that because if they leaked, all the work I did would have have been down the drain. Couple notes.............

The screw plates are a PITA to install.

Leave the covers for the heat shields on so they don't get scratched when installed. They are wrapped all around so just remove the inside part so the clamps can be installed. I removed them and ended up taping the shields.


I ran into a problem when installing the CFR's, hopefully someone can offer some advice. I went to install the left side CFR, no problems. Went to install the right side and it won't go on past about a 1/4". No matter how much I pushed, pulled, or twisted. I took the old header and installed it into the muffler to try to open it a bit. I did get it opened a bit, but still isn't far enough over the headpipe. Next I took some emery cloth to try to remove some of the plating on the new headers. Didn't work, still not moving far enough. Next, I take a towel, a 2 X 6 and a hand held sledge. You can pretty much figure the rest out. It moved it a little more, but still not enough because I tightened everything up and heard a leak. I can also feel some exhaust escaping right at the muffler clamp. Took a look at the clamp and saw it wasn't close to the end of the muffler. I loosen it and move it more towards the end of the muffler and tighten it again but, still leaking. So I remove the whole muffler and it's sitting in my garage.

Here is what I think I can do to solve the problem. Obviously, the opening of the muffler isn't large enough to install over the header pipe. The edge is open enough, but somewhere it's hitting and not moving. I was thinking I could take the muffler to a muffler shop to have them open it up a bit with their hydraulic pipe bending machine.

What do you guys think?

 

Hey r8rs4lf,
I had a buddy with the same problem of getting the muffler over the header. A $7 muffler pipe expander tool from Harbor Freight solved the problem.

BTW, don't use any RTV ahead of the O2 sensors. Even a small amount can play havoc with them. (Not an issue at the header to muffler joint)

 

Well OK then! I have a HF close to me so I'll go check that out first thing tomorrow.

Found it. Seems there are three different sizes. I guess I'll walk in with a nice flat black CFR muffler in hand.

http://www.harborfreight.com/catalog...ols&q=expander


Thanks for the info!!!!

 

That's exactly what I did. Took my CFRs to my local Meineke shop and although the guy was reluctant, he did expand them a tad. Maybe a 1/16", no more. Gave him enough to buy 2 beers and that was it. Worked like a charm.
Remember that in order to stop leaks, RTV Red works great. I also helps slide the mufflers over the head pipes and align them with the rear brackets.

 

I'm a little reluctant to use the RTV because I don't want to have to deal with it if I ever have to remove the muffler again. You know it will happen sometime down the road.

I'm going to try the HF tool first. That way I can control how much the opening is being expanded. I'm sure it will work. Plus it's another tool to add to the toolbox!

Many thanks FB! You have helped me alot with my exhaust. I appreciate it.

 

I love tools but only the ones I know I'm gonna use more than once, plus my local HF store is 10 miles further than the Meineke shop.

I hear you with the RTV but FYI, pulling the CFRs out of the headpipes was already a PITA without RTV. I had to yank them pretty hard up and down and side to side, sitting on the garage floor behind the bike. My back hurt for 2 days. lol

Anyway, you're gonna be a happy man when your Dresser Duals are on. You're not gonna believe the difference in sound.

Let us know when you're done.

 

OK, new day and new story............

Got up and went straight to HF to get the muffler expander tool. Got home and started going at it. A couple times I hear a snap......... Uh Oh!!!! Take the tool out, look at muffler thinking I just split it somewhere. No split, go to try to install it, got a bit more of the muffler over the headpipe. Remove it, install tool, crank on it, another snap........ OH DAMN!!!!!! Thinking the same thing, remove the tool, nothing. Go to install it, I get a bit more over the headpipe. Can you tell this is going to be a slooooow process? Go to install the tool and I see what the snaps were about. The piece that actually expands in the muffler had two broken pieces. What a POS!!!! I say to myself, that's what I get for going to that cheap china $h*t store for a tool. Toss that thing to the side, cover up my muffler and head to the muffler shop.

Guy there tells me he needs the headpipe. I say it's on the bike and it was a PITA to put on so no way I'm going to remove it just for you to expand my muffler. He say OK, but I'm not going to guarantee............... YADA, YADA, YADA! Just do it. He does it, I ask how much, he tells me to try it out first and come back. I say cool and I leave.

Get home, it slides right on!!!

I button everything up and go to start it and OMG, it sounds BAD @$$!!!

I go to rev it up and no pop , backfire or anything, just a mean @$$ sounding exhaust.

Clean up all the tools, grab my helmet and head off for a quick 20 minute ride to see where the tune is. I get no decal pop or anything. Seems the tune is ok for now. The biggest thing I notice is there is no heat on the right side anymore! That's exactly what I was looking for!!!! The sound is just an added bonus!

I have to take my daughter to school soon, but I plan on taking it out for a freeway run to Harbor $h*t to return that POS tool. That's when I'll be able to tell for sure about the heat and tune.

FB, I still may install your tune just to see what differences I get if any.

Overall, I'm very, very happy with the dresser duals besides the fact I had to go through all that drama because the headpipe was too big. I'm assuming it's the plating that made it thicker than usual.

 

See, ya shoulda listened to me when I told you to go see Meineke. lol

Glad things worked fine and glad to know you're liking your headers.
I had a little bit of popping at decel so I added 10% between 2,000 and 3,750rpm at 0% throttle. So far, no more popping.
Oh and check your clamps and header nuts. They'll have to be re-tightened when the pipes are hot.
Have fun.

 

Yup, should have just went direct. Oh well, got my money back for that POS tool.

I checked all the clamps before I left for the ride. I'm going to check them again after it cools down because I just got home from a longer ride.

A couple of more notes after riding for a good two hours..........

The heat on the right side is still there, but not even close to what it used to be. It's hardly even noticable. I'm sure I could all but get rid of it if I were to ceramic coat the headers.

The sound is incredible.

Ride safe..................