Need some help installing Jackpot header...
I got mine used from a guy here on the forums. His was an 11 model and was using the 12m bungs. He had plugs in the 18mm bungs that I have to use on my 09. One gave me problems and I had to let it soak in wd40 for a few hours, and it was still a B*^h to get out. I don't think that I tweaked anything but I am not discrediting that possibility just yet.
Road Master
Joined: May 2008
Posts: 1,065
Likes: 1
From: Madison, WI
I have done this dozens of times. It is finesse and not force.
One key is to tip the bottom out as you bring the header towards the cylinders first. It will actually fit in there without touching the fins if you are careful.
The next step as you move the bottom in towards the bike is to be sure the header tab gets below the tranny bracket.
Then go back and slide the flanges on the bolts up top.
Start all the bolts and then tighten as per the manual.
Easy on those exhaust flange bolts, 100 inch pounds is enough.
Save some headaches and use the stock exhaust gaskets. The header was designed for them. I have tried others, inculding the SE and the stock are best for fit and performance.
One key is to tip the bottom out as you bring the header towards the cylinders first. It will actually fit in there without touching the fins if you are careful.
The next step as you move the bottom in towards the bike is to be sure the header tab gets below the tranny bracket.
Then go back and slide the flanges on the bolts up top.
Start all the bolts and then tighten as per the manual.
Easy on those exhaust flange bolts, 100 inch pounds is enough.
Save some headaches and use the stock exhaust gaskets. The header was designed for them. I have tried others, inculding the SE and the stock are best for fit and performance.
I called my mechanic back and told him that there are only 2 options (1) the headers is not in the head properly or (2) the header is tweaked. He put me on speaker and did a test (to him) and tightened on the header bolts at the heads. The bottom kicked out away from the bike even further. Not sure what to think, but I am going to try and go over there tomorrow...if the weather is nasty...if not he is going to go riding. I can't blame him. Hopefully he was just having a rough day and it goes on properly next time he tries it.
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?
__________________
Jamie Long / Fuel Moto USA
The USA's Leader V-Twin EFI & Performance www.fuelmotousa.com
Contact 920-423-3309
Email jamie@fuelmotousa.com
Jamie Long / Fuel Moto USA
The USA's Leader V-Twin EFI & Performance www.fuelmotousa.com
Contact 920-423-3309
Email jamie@fuelmotousa.com
Jamie, I have to give you and your team serious credit. Posting on the weekend with advice to install one of your pipes secondhand is the reason I will continue to keep buying from you!!
My mechanic followed your instructions and it went in easy! Thanks again.
My mechanic followed your instructions and it went in easy! Thanks again.
Thank you for the update and continued support
Road Warrior
Joined: Feb 2010
Posts: 1,534
Likes: 10
Jamie-What exhaust gaskets do you recommend using?
I used the stock HD exhaust gaskets with your head pipe, but when I later removed the pipe do do cams, I noticed that the stock exhaust gaskets were crushed, obstructing the flow of exhaust gases (imagine what a clogged artery looks like).
Some Folks here say to only use the SE gaskets, others say to only use the stock HD tapered gaskets.
Which do you recommend for this application?
Thanks
I used the stock HD exhaust gaskets with your head pipe, but when I later removed the pipe do do cams, I noticed that the stock exhaust gaskets were crushed, obstructing the flow of exhaust gases (imagine what a clogged artery looks like).
Some Folks here say to only use the SE gaskets, others say to only use the stock HD tapered gaskets.
Which do you recommend for this application?
Thanks
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Elite HDF Member
Joined: Jul 2008
Posts: 4,741
Likes: 45
From: Indian Land, SC
Jamie-What exhaust gaskets do you recommend using?
I used the stock HD exhaust gaskets with your head pipe, but when I later removed the pipe do do cams, I noticed that the stock exhaust gaskets were crushed, obstructing the flow of exhaust gases (imagine what a clogged artery looks like).
Some Folks here say to only use the SE gaskets, others say to only use the stock HD tapered gaskets.
Which do you recommend for this application?
Thanks
I used the stock HD exhaust gaskets with your head pipe, but when I later removed the pipe do do cams, I noticed that the stock exhaust gaskets were crushed, obstructing the flow of exhaust gases (imagine what a clogged artery looks like).
Some Folks here say to only use the SE gaskets, others say to only use the stock HD tapered gaskets.
Which do you recommend for this application?
Thanks
Since these aftermarket pipes are not tapered like the HD pipes, I hope those torque specs are correct because I just installed MGS Duals and used the 100 in/lb spec for the first go around until I can heat cycle them a few times.
Maybe FM can chime in as far as what they torque the flange nuts to..........
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