Well here is my predicament. I am currently in the process of installing the FM 2-1-2 head pipe onto my 2011 ultra limited. I have run into some problems and could use some help...

1. Is the head flange suppose to be flush against the motor after everything is torqued down? It just looks like there is alot of extra space compared to the factory head pipe. ( don't know how to take a effective picture of what I'm asking)

2. Does anyone have a trick to torque the lower flange nut on the front head? I used a universal joint adaptor and it feels like I got it but I want to make sure.
3. How the hell do you get the gasket on/in the crossover pipe?

I have been following the service manual by the letter but this is kicking my ***... Now I know why labor is 85 dollars an hour.

Also is everyone else on this forum NASA mechanics? This has been an embarrassing first attempt at wrench turning, y'all make it sound way to easy.

 

2. I reach one of the nuts with an extension and go straight in. The other I use an open end on it. Tighten em evenly, making sure its going in right.

 

i used same tools and ended up buying new crossover gasket

 

Question 1 - The extra space you're seeing is perfectly normal. The FM pipe has a more substantial "step" than the factory pipes simple "crimp".

Question 2 - Already answered in the previous post.

Question 3 - Are you sure the original gasket isn't in the crossover? If it stayed in just re-use it. If not, install the new gasket into the crossover pipe and then slip it onto the header. If it gives you trouble you may need to use a pipe expander on the crossover.

And yes - I was an aerospace techinician/engineer working on NASA and DOD stuff for many years LOL.

 

Well I finished it.....that was a pain. Few more questions I loaded the map from fuel moto and after it was done it asked me a yes or no question about the air fuel table, I selected no, I tried to call FM but they are closed so hopefully someone here knows. Also, is the dish soap and water in a squirt bottle the best way to check for leaks. Thanks again for all of the help.

-Number

 

Also does the power vision back up your stock map? I watched the video on FM website but it appears that was an older version of the PV, because I did not have the option to do it myself .

 

Sorry I can't help you on the PV questions. I'm just not familiar with that unit. I have the PCV w/Autotune.

As for leaks, I don't think soap solution will work. It may, but you won't have much time. You'll need to work very fast before the exhaust heats up. I would simply listen at each joint for anything obvious. If you don't hear anything you're probably ok. Then to double-check, after you ride it a while take a look at each joint for any tell-tale signs of leakage. If it's leaking you should be able to see a "soot" trail.

 

Congrats on taking it on. I just received my FM 2-1-2 a week ago and was going to do it myself but my HD dealer is offering half price labor right now, so they will be installing soon. If you get a chance, post your opinion on sound & power. Happy New Year!

 

i can't be 100% sure cause the pv has changed a lot since i got mine, but from what i understand, it automatically saves a backup of your original map now.

*edit* i connected the pv to my pc and took it out of pc connect mode. from the base screen, i selected 'load tune'; then selected 'load copy'; then selected 'load copy of original'; it then came up with a message that read, ' this type of tune file is a copy of the tune that was present in your ecm when the powervision first locked to your ecm. so it would appear that it does automatically back up when first married to your bike.

check out this thread, there is a lot of discussion on the pv, with some downloads and other stuff thrown in there. don't be intimidated by it, some folks will take it very deep, but it doesn't have to be any more in depth than flashing a new tune and then putting the unit away in your toolbox (unless you want it to...)

https://www.hdforums.com/forum/elect...-by-admin.html

 

Thanks for the responses, its suppose to be in the 60's tomorrow so I will take it out for a test ride. Fingers are crossed. Skratch thanks for the link, I will dive into it.