I marked and cut the 2010 headpipe in half at the center of the cat. I drilled 1/4 holes through the cat material all the way around the edge of the headpipes. I then used a 1/2 bit and drilled out the cat material. This was the best way I found to remove the cat material.

 

Can a 09 head pipe be used on a 2010? I know the O2 sensors are in different locations, but I have eliminated them anyway when I installed the PCV so that doesn't matter. Just want to get rid of the cat w/o overspending. I found a 09 set for a real good price. Just wanted to be sure they would work.

 

I have done 2 myself, both using a cutoff blade on a 4" grinder and cutting a whole in the side of the collector. It is really not that hard and you do get all the cat material out. I cut one out on the inside of the collector (bike side) and one on the outside (shield side). If you cut it out on the shield side you can not tell its been done no matter how hard you look. Took it to a muffler shop they welded it back for $20.

 

Any pictures? Or measurements of where and how much you cut?

 

i cut mine in half, beat the innards out, then had it welded back together. if you look close, you can see the weld line that circles the cat, but its not an issue. it is no problem to get everything lined up back for mounting.

one thing to be aware of, the cat material is not as easy to get out as it used to be. it took about an hour of beating, digging, and using a wire brush to clean it up to get it good and clean. unfortunately, i saw the post on using a air hammer after i had already done this.

i used a digital thermometer to measure the temp at the collector, where the cat was to check the heat after a long ride and it was right around 475*.... didn't think to check it before hand, but if someone else wanted to, that would be cool. digital stick thermometer at harbor freight, $4.99.

 

I picked up an 09 headpipe w/o cat for $60.00 w/shipping. Since my O2 sensor are disconnected for use of my PCV on my 2010 I figure I'd plug the sensor holes on the 09 pipe. Has anyone used an 09 headpipe w/o the cat on a 2010. I was going to cut the cat out of my original pipe but for $60.00 I'll keep the 2010 pipe in case I need it in the future for a warranty isssue.

 

Sorry sold one of them the other is on the bike. With the pipe off of the bike, stick a tape measure in the pipe till it hits the cat. The cat is 5" long from that point its easy to see where to cut. Probably a 4 1/2" to 5" by about 2 1/2" to 3" hole in the side of the collector. You have to pry the side off of the collector. To get the cat out I drilled some holes in it, then hammer and chissel. You will have to have a couple different chissels to get the small pieces stuck to the sides of the collector. It will take an hour or so, depending on what kind of tools you have. I am not a good welder so I took to a muffler shop, any good welder can do it.

 

So will the Dealer sell me a Non California Header for my 09 CA Model Streetglide?

If I swap out my Header with the CAT for one without the CAT will my canned PCV Map from Fuel Moto still be correct or does it need to be adjusted?


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