Fuel Moto header Install Question
Road Master
Joined: Aug 2012
Posts: 1,156
Likes: 27
From: Texas
The clearance between the front header and the brake actuator is now at about 3/16". I still think that with the engine shake it will be hitting the pin.
I worry that the exhaust flange gaskets will be ruined after all this tightening, loosening and repositioning of the header.
Has nobody else had this much trouble installing these?
I have put it away for tonight and will try again tomorrow when I have cleared my head.
I worry that the exhaust flange gaskets will be ruined after all this tightening, loosening and repositioning of the header.
Has nobody else had this much trouble installing these?
I have put it away for tonight and will try again tomorrow when I have cleared my head.
My 2-1-2 is the standard FM header. FM makes a 2-1-2 for larger displacement engines and this pipe has a larger diameter, that's why I asked about it in my earlier post. Look on their website for the stock numbers, then check your invoice to see what they shipped you.
I don't think you'll have a problem with ruining the exhaust gaskets. I've had my system on & off several times and they've never leaked.
While I've never heard of anyone having a problem, that doesn't mean it hasn't happened. I'm sure that the pipes are bent, then placed in a jig for welding, so there may be some small margin of error, but not much. I guess if the pipe were dropped during handling/packaging, it could have been knocked out of alignment.
The header can only line-up one-way, fitting into the exhaust ports and positioned where they can bolt to the bracket located below the "Six Speed" cover on the transmission. Once you get it attached & tightened at these 3 points, then concentrate on fitting the cross-over pipe & bracket that attaches it to the end of the transmission/oil pan. Loosely attach the left muffler to the cross-over and muffler supports, then begin tightening and aligning.
Stopping for the night is always a good idea, especially when you're tired, frustrated and cold.
Give it another try tomorrow and if you can't get it to fit after the first try, give it a rest and call Fuel Moto on Monday. They have the best Customer Service of anyone I've ever dealt with and will take care of you.
Let us know what happens and Good Luck!
Road Master
Joined: Aug 2012
Posts: 1,156
Likes: 27
From: Texas
I believe Fuel Moto will want to send another pipe and get this pipe back. This is one reason I like to decat the stock head pipes and use them. There's no fitment problems with the stock head pipes and I haven't seen any advantage on the dyno using aftermarket pipes with stage I or just a cam change.
Billy
Billy
Advanced
Joined: Sep 2009
Posts: 62
Likes: 0
From: Roswell, GA
Best of luck to you... I'm in the middle of the same thing with Fuel Moto's sending my V&H Dresser Duals. I asked them to send gaskets, they said ok... No gaskets... now wait for the dealer to open. Sigh////
Road Master
Joined: Aug 2012
Posts: 1,156
Likes: 27
From: Texas
If the factory exhaust gaskets are still intact, just reuse them.
Tourer
Joined: May 2011
Posts: 300
Likes: 6
From: South Carolina
I didn't mean to hijack hdmg's thread. It looks like he's having some of my luck and I'm sure Fuel Moto will take care of him. We like for stuff to fit right on but sometimes it doesn't.
Billy
Road Warrior
Joined: Dec 2012
Posts: 1,335
Likes: 5
From: CT
I'm going by what I'm seeing at my local dyno but not on compleatly stock motors. The stock decatted head pipes are not giving up anything to after market pipes. I know from experiance that you'll see slightly differant #s from one day to the next on a dyno. A couple of hp/tq is not enough to feel.
I didn't mean to hijack hdmg's thread. It looks like he's having some of my luck and I'm sure Fuel Moto will take care of him. We like for stuff to fit right on but sometimes it doesn't.
Billy
I didn't mean to hijack hdmg's thread. It looks like he's having some of my luck and I'm sure Fuel Moto will take care of him. We like for stuff to fit right on but sometimes it doesn't.
Billy
I think getting rid of that 15 lb stock behemoth was well worth the money... Not to mention I think it makes the whole system sound better. And 2-3 HP on a 65-70 HP motor is a step in the positive direction. JMO.
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Tourer
Joined: Apr 2007
Posts: 424
Likes: 4
From: Denver, CO
I loosened everything up and tightened the transmission mounting flange first to get to sit tight against the bracket. Then I tightend in the exhaust flanges slowly and carefully in 20 in/lb increments to 110 in/lbs as per the manual.
The clearance between the front header and the brake actuator is now at about 3/16".
I still think that with the engine shake it will be hitting the pin.
Anyway the right muffler goes on niceley but when I install the crossover pipe, the left muffler angles in too far towards the inside of the rear wheel and takes considerable force to pull it out enough to get the muffler mounting bolts in. This is definately not right.
If I move the crossover out any more towards the left side of the bike there is not enough engagement with the header pipe.
I spent 3 hours in 38 degree weather messing with this damn thing!
ARRRGH...IF I NEVER DO THIS AGAIN IT WILL BE TOO SOON!
Damn am I frustrated with this. I am very mechanically inclined and do all my own wrenching on my cars and bike.
I have never had this much trouble before. It's like the geometry of the pipes is not quite right.
I worry that the exhaust flange gaskets will be ruined after all this tightening, loosening and repositioning of the header.
Has nobody else had this much trouble installing these?
I have put it away for tonight and will try again tomorrow when I have cleared my head.
The clearance between the front header and the brake actuator is now at about 3/16".
I still think that with the engine shake it will be hitting the pin.
Anyway the right muffler goes on niceley but when I install the crossover pipe, the left muffler angles in too far towards the inside of the rear wheel and takes considerable force to pull it out enough to get the muffler mounting bolts in. This is definately not right.
If I move the crossover out any more towards the left side of the bike there is not enough engagement with the header pipe.
I spent 3 hours in 38 degree weather messing with this damn thing!
ARRRGH...IF I NEVER DO THIS AGAIN IT WILL BE TOO SOON!
Damn am I frustrated with this. I am very mechanically inclined and do all my own wrenching on my cars and bike.
I have never had this much trouble before. It's like the geometry of the pipes is not quite right.
I worry that the exhaust flange gaskets will be ruined after all this tightening, loosening and repositioning of the header.
Has nobody else had this much trouble installing these?
I have put it away for tonight and will try again tomorrow when I have cleared my head.
Even with the help of my neighbor, the tolerances were unbelievably close.
Finally called Fuel Moto and they sent me their thinner crush washers for the exhaust ports. The regular ones from Harley with the tapered fit... they did not allow the header pipes to line up.
I'm pretty good of a wrench and so is my neighbor. The fitting was a total pain in the you-know-what.
I've been having problems with the crossover pipe not fitting on properly to the header pipe. This has been since day one.
Don't know it it's an alignment or diameter of the header pipe problem. Darn crossover pipe cannot be tightened securely on the header pipe.
Local Harley said the same thing.
I'm going to remove the crossover, get some spreaders, already have a new gasket, and will wrap gasket with high temp tape and then install a new clamp on the crossover/header connection.
Good luck and keep up informed as to your success.
Seasoned HDF Member
Joined: Apr 2006
Posts: 10,675
Likes: 95
From: Billings,Mt.
I went thru the samething,just did not seem to fit right.I could swear that the outlet from the FM stainless is not not aligned correctly but Jamie said no.