Do I really need to remove the entire exhaust on my 2007 FLHT to remove my old/and replace with new clutch cable? It looks like another project entirely. I have replaced the mufflers before, but it looks like to get at the cover and the 3/16 allen heads, I need to remove most of the exhaust.

If I have to remove the entire thing, do I need new Torcas along with new header gaskets?

Any tips or tricks? I do have the manual already.

 

I recently had my clutch cable replaced under the extended warranty (it was leaking), and they did indeed have to remove most of the exhaust. I was able to take advantage of that and have them reinstall a new set of V&H headers instead, which they did at a greatly reduced labor charge since they already had the old stuff off.

 

loosen the right hand rear bracket and remove the bracket near the floorboard...you have to do this to get to the transmission cover. So technically you don't have to remove the whole exhaust. i wouldn't mess with the header bolts and break that seal ...it's a pain in the ***.

 

I changed mine on my 08 SG, I just cut down an allen wrench short to the point it just fit in the bolt. Loose a little at a time, took a while but I didn't have to take the exhaust off.

 

I took the bracket near the floorboard off. I can take off the bracket for the muffler support. Is the idea that there will be enough play once these are both removed without taking the entire exhaust off? It looks tight. I do have ball Allen wrenches.

 

If I remember right, the problem is getting to the lower bolts on the clutch cover. I took one bolt off the floorboard, loosened the other so I could swing it out of the way. I also slipped off the muffler and loosened the exhaust head bolts so I could move it out of the way enough to get to the bolts. Sometimes it takes less time to move a part out of the way then have to fight it. Make sure you replace the cover gasket.

 

According to the manual, the torca clamps are a 1 time use only. I have had luck with being able to re-use them before, and also them not working when I tried to re-use. It's a crap shoot.

 

Check out pages 6 and 7 of my DIY. My RKC is an 07 so should be identical.
You don't have to remove everything

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