I just purchased a 2004, 1200XLC Sportsterandneed some advice from you seasoned Sportster riders. I am in the process of installing a set of SE II Slip-On pipes, have everything disconnectedto the point of removing the stock pipes.Here's my question - Since the muffler fits into theblack interconnect pipe at right angles to the header pipe, its difficult to slip the muffler straight back without either loosening the interconnectbracket/pipe or removing the header pipe from the cylinder. It looks like removing the header pipes would be the easiest sincethere are only 2 nuts for each pipe.If I just loosen the header pipes, I'm afraid the gaskets won't seal. What do you guys recommend? Do you have any other suggestions? I searched the various threads but was unable to determine the best approach. Thanks for the help.

Jerry

 

I just loosend the header pipes & had no problems , just make sure you check for leaks ,Mine sound Grrrrrreat !

 

You're damn right you'll get leaks! I just made a thread about this yesterday after installing pipes about a week ago and having a leak problem. Basically, my dad redid the whole exhaust with new gaskets to fix the leak. I think his method was tighten the mufflers to the interconnect tube, then tighten the pipe to the exhaust port. Leave the part where the muffler connects to the pipe loose while doing this so that it sits "naturally," and the muffler clamps completely seal it up at whatever angle that happens to be due to the huge amount of torque you apply while tightening them.

Here's the thread about our discoveries:
https://www.hdforums.com/m_2338186/tm.htm

 

Oh, and you might want to pick up some Screamin' Eagle gaskets for the exhaust ports while you're at it. I bought some when my dad redid my exhaust, and they are much thicker and of better quality.Also, we discovered that when we were taking off the old slip-ons, and the pipes moved around a bunch, they were actually smashing the original gaskets. They were pretty badly disfigured when we went to replace them.

So I guess you should buy new interconnect gaskets and new exhaust port gaskets. Then follow this:

1) loosen all connections of the exhaust
2) disassemble the whole thing
3) place the mufflers onto the exhaust pipes while it is disassembled
4) replace the muffler interconnect gasket by placingit onto the interconnect pipe -- not in the muffler's port
5) place the muffler carefully over the interconnect gasket to connect it to the tube
6) tighten down the muffler to the interconnect tube
7) place the new exhaust port gasket (hopefully you bought screamin eagle) into the exhaust port
8) connect the pipe (while it is loosely connected to the muffler) into the exhaust port
*** be sure you have the muffler clamps,etc.on the pipe PRIOR to connecting it***
9) tighten down the pipe to the exhaust port
10) repeat 4-9 for the other muffler
11) tighten the muffler clamps after the muffler/interconnect andpipe/exhaust portconnections have been made on both pipes so that the muffler/pipe connection is "relaxed" and "natural"
12) tighten down the middle connector for the rear pipe last
13) replace heat shields
14) enjoy the leak-free ride

That should pretty much do it.

 

For what its worth on my 07 custom - installed some cycle shacks a while back. Thought they sounded a little louder than I expected and started to get some popping on deceleration espically quick decleartion. My buddy had the same pipe and we compared and his was quieter so Iam thinking hummmm - well later that day I hear a rattle in area of pipes - investigate further and low and behold one side of the exhaust was completly missing the nuts that held it in place. Must have been "FM" as I never touched them to put on the new pipes. Oh well trip to the hardware store and walla all is well !
Kirt

 

JC - Thanks for the detailed instructions. They were right on the money. Pipes sound great and no leaks.

Thanks,
Jerry

 

No problem, glad I could help.

 

I've installed slip on mufflers on several Sportys. I found the easiest way was to just totally remove the header pipes. Never had any problems with exhaust leaks.

 

Right, that's why I suggested it.

 

Thats what I did when I had to remove the rear muffler to get the rear tire off. Took the entire exhaust section off at the header.

Tom