Need some help installing Jackpot header...
Intermediate
Joined: Dec 2012
Posts: 46
Likes: 0
From: Louisiana
Installed mine last night with old gaskets only 2000 miles on them was a little tough to line up but I would get one or two threads started then take a socket and extension and push the flange opposite the one I just started wiggling the header as I went then start second nut .Then move on to next cylinder . then run them down evenly . I then tightened them to 90 in lbs .
Don't know if it matters mine are the 2/1 but should be the same flange
Don't know if it matters mine are the 2/1 but should be the same flange
i put the header on my new bike 200 miles, used the stock gasket you have to be carefull and get both nuts started then tighten, if it still dosent fit, fuel moto sells a much nicer gasket that is not as thick, used it on last bike. the pipe is well worth the trouble.
Road Captain
Joined: Sep 2011
Posts: 541
Likes: 3
From: Sherwood Park AB Canada
I should clarify on the SE gaskets. The SE gaskets are a little thicker than stock HD, making it even more difficult to get the flange nut started. Because of the squared off flange on the Jackpot rather than the tapered one on the stock pipe, the flange does not go into the head as far. As you can see, even with the stock gasket it is quite tight, but with some work you will get there. I, like others, left the old ones in place rather than replace with new and have had no leak issues. I suspect that the old gasket was slightly pressed compared to new, so the pipe flange was somewhat easier to get started. That said, I did have to work at it to get enough thread on the stud to protrude so I could start the nut. Trust me though, once installed, you will be very happy with the Jackpot pipe, it seems to be very well engineered to get the most performance.
Road Captain
Joined: Sep 2007
Posts: 500
Likes: 2
From: Springfield Ohio
Also double check that you don't have the flange flipped. There is a groove cut in one side the captures the split ring. If you can see that groove (right around the pipe) the flange needs to be removed and flipped over.
Not to hijack the thread but my mechanic just called and he is having some trouble installing my headpipe on my 09. He has the bolts started in the heads (not tightened but on) and the support at the transmission will no slide under the tab. Has anyone had this problem? Is there a step that he is not following.
He was going to try and grid the bottom of the tab so that it would fit on top instead of on bottom, but I don't think that is a good idea. I did have a hell of a time getting the old plugs out of one of the headers. Is it possible I tweaked them when I was wrenching it out?
He was going to try and grid the bottom of the tab so that it would fit on top instead of on bottom, but I don't think that is a good idea. I did have a hell of a time getting the old plugs out of one of the headers. Is it possible I tweaked them when I was wrenching it out?
Last edited by Stang951; Jan 12, 2013 at 04:40 PM.
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Elite HDF Member
Joined: Jul 2008
Posts: 4,741
Likes: 45
From: Indian Land, SC
Not to hijack the thread but my mechanic just called and he is having some trouble installing my headpipe on my 09. He has the bolts started in the heads (not tightened but on) and the support at the transmission will no slide under the tab. Has anyone had this problem? Is there a step that he is not following.
He was going to try and grid the bottom of the tab so that it would fit on top instead of on bottom, but I don't think that is a good idea. I did have a hell of a time getting the old plugs out of one of the headers. Is it possible I tweaked them when I was wrenching it out?
He was going to try and grid the bottom of the tab so that it would fit on top instead of on bottom, but I don't think that is a good idea. I did have a hell of a time getting the old plugs out of one of the headers. Is it possible I tweaked them when I was wrenching it out?
If the nut is loosened on the bolt, the exhaust tab should slip under the bracket attatched to the bike. If the pipes will not angle down for this to happen, there's issues with the positioning of the pipes into the heads.
Also what plugs did you remove from the headers?
Last edited by HDV-GLIDE; Jan 12, 2013 at 04:57 PM.
Thread Starter
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Road Captain
Joined: Jan 2010
Posts: 527
Likes: 42
From: Sequim, WA
Thanks for all the replies! I guess I just needed to walk away from it for a while. I ran out of light when I first tried this. Had time to work on it this morning and everything went right in place. I uploaded my new map from Fuel Moto using the Power Vision and went for a nice ride. Pretty sweet!! I'll recheck all the nuts and bolts when it cools down.