When my son Dale bought a 2008 Harley FLHTCU it didn't take him long to ask me what he could do to the exhaust system.
My answer, “a lot.” He needed to be more specific, but he was drunk. There's so much a guy can accomplish with a change, as different systems provide different results. What we came up with was to use a true dual system so the appearance of the motorcycle would not change drastically, and there's other benefits.
The D&D Duelie pipes (part 516-22D) were chosen because they looked good and would enhance performance by giving the rear cylinder its own pipe providing a true dual exhaust. Adding a set of D&D 3.5- inch slash cut mufflers (part 408-12S) would produce a good sound without being offensive.
It wasn’t until I actually received the exhaust that I saw the quality of construction, heavy gauge of the metal, with oxygen sensor bungs welded in place, flawless chrome, and heat shields already installed that I really became impressed. D&D offers another exhaust system benefit. Each one is dyno tested and tuned. The D&D staff are avid land speed record nuts, and their pipes are a large portion of the tuning equation. Bandit ran D&D tuned exhaust on the Assalt Weapan at Bonneville in 2007 for a top speed of 162 mph.
I started off by removing the saddlebags so everything was easy to reach. Next move was to remove the factory heat shield with a 5/16-1/4 drive socket (a common screwdriver may also be used).
Using a 9/16” socket I loosened the clamps at the mufflers and sprayed the joints with PB Blaster penetrating oil. While it was working I went to the rear of the muffler and used a 1/2 inch socket to remove the two bolts from the muffler bracket under the bags. The muffler was removed by shaking loose and pulling on the stuck bastards. Exhaust does nasty shit to fasteners and connections, be patient.
I disconnected the wiring for the Oxygen Sensors but opted not to remove them from the pipe until I had it off the bike. It's always a good notion to disconnect the battery. It wouldn't seem to be necessary in this case, but if sonny boy had a brand new exhaust system in his hands and caused a short with the pipe across the starter and paniced, he could drop and damage the pipe.
From the left side of the motorcycle using a 3/8 ball end Allen, with a extension, I removed the right floorboard where the brackets joined the frame under the bike. Removing the clamp on the pipe by the transmission and the two nuts holding the pipe to the head it came off easily.
The pipe on the left side was removed in the same manner. It should be noted that the bracket tab on the rear exhaust support bracket was also removed. There was no need to remove the exhaust flange off the old pipes as the new pipes have them on already. Lots of new exhaust systems don't come with shit from the factory, but that's not the case with D&D. They supply most of the fasteners, spacers for the floor boards and mufflers, the flanges in place and the heat shields installed. You just need the exhaust flange nuts and new exhaust head gaskets.
With the factory system removed the exhaust gaskets were replaced in the head and the Oxygen Sensors were removed from factory pipes and installed into the new ones. A small amount of Anti-Seize was applied to the threads with care taken not to get any on the sensor tip! I torqued them to 30-44 Foot lbs.
The right side pipe was fitted to the head. All the fasteners were installed all the way to the muffler loose and checked for position and fit before tightening, beginning at the manifold and working back. Then using a ½-inch 3/8-drive socket the top nut tightened. I was pleasantly surprised to find a cut out in the heat shield for the bottom nut that allowed the socket to fit without the problems that I have experienced with other systems. Clearances were checked and the bottom nut on flange tightened to 100-120 inch lbs. followed by the top one to the same specifications.
The tranny bracket welded to the pipe fit the bracket on the transmission without shimming. The muffler slid in with ease and could be felt to bottom out on pipe lip. The clamp was tightened enough to hold muffler in place as the two black spacers provided in kit were installed under the saddle bag hanger to align the muffler with the entire system. Some bikes need the spacers, others don't. The bolts were torqued to 96-144 inch lbs while alternating tightening. The muffler clamp was not fully tightened at this time.
Moving to the left side of the motorcycle the rear pipe was installed in the same manner as the front. I use a piece of folded cardboard between the trans and primary and the pipe, to hold the pipe in position until I install fasteners. Once everything is in place all fasteners are tightened from the manifold back.
From the rear of the motorcycle the mufflers were positioned so they are even and then the clamps were fully tightened. While I was connecting the wires for the Oxygen Sensors and re-installing the floorboard, with the spacers provide in the kit, my helper installed the side covers and saddle bags. A final check was made that everything was installed and tightened properly.
Even though I use gloves while doing the job the pipes were wiped clean just to make sure there wasn't anything on them that would leave a stain when the pipes got hot. I cure the chrome by running the engine at idle speed for about one minute. Let motorcycle cool and repeat 3-4 times.
Depending on your motorcycle you may have to make some adjustments to your fuel system. I rode the motorcycle and was quite happy with how it sounded and performed. I also did a sparkplug color check and everything got a thumbs up!
I mentioned to my helper that I do not remember the last time a job went so well and everything fit like it was suppose to. He had recently installed another brand of exhaust on his bike and said it was a lot of work to get it to fit correctly.
To keep the pipes clean, wipe down with Rubbing Alcohol and shine with Glass Cleaner. DO NOT USE HARSH ABRASIVES!
When I delivered the bike to my humble son, Dale, and told him to take it for a ride, the Big Smile on his face told me we made the right choice with a D&D exhaust.
For more information on D&D and their products check their website http://www.danddexhaust.com/ or contact their office at D&D Performance Enterprises, 2923 Edith Lane, Fort Worth, Texas, 76117. Phone 817-834-8961
–ROGUE
