....i just got my exhaust setup in the mail today. Vance and hines dresser duals and CFR mufflers. The problem i'm having is that the right side head pipe will not easily slide into the mufller...i had to try to bang it in, and even when i did that its still not clearing the slits in the sides of the muffler all the way. The left side pipe had no problem, and i even checked both mufflers on that side and they fit perfect....What can i do to make it fit without running into exhaust leak problems etc...Please help before I punch another dent into my toolbox

 

See if you can borrow (or buy) a pipe expander. Here's one on Amazon...

http://www.amazon.com/Exhaust-Tail-P.../dp/B001Z0RF1G

 

Stop punching things, take a 10 minute breather, then go back. Try to open up the opening of the exhaust pipe some, use a tool, or if the pipe starts to slide on a little move it up, down, and side to side, to "work" it in there. Just have some patience. Also try to lay underneath it and make sure it starts on straight, you will find the right angle and everything will be ok. Worst come to worst, take the mentioned muffler to a local exhaust shop tomorrow and ask them to open it up a bit on the end, they might do it for free or charge you next to nothing.

 

WD-40 and be sure to wipe all excess off before starting up.

 

I just had the same problem with my Fulsac True Duals. 2 buddies fit fine. My right side muffler wouldn't go in as far as the stock Y-pipe. I took the pipe over to the wire wheel on my grinder and removed some of the coating. Since mine was a single pipe, I was able to take the pipe, turn it upside down and drive the muffler on it with my hands, hitting the pipe on a 2 X 4 on the floor.

My luck, it will rust out in no time now.

 

I ran into this years ago when I installed a set of V&H duals. Check for any burrs on the inside of the header pipe. I had to use my dremmel tool to grind down the surface area inside the header pipe a little bit to get the muffler to side on.

It's a PIA for sure, but it will eventually fit.

Good luck!

J.B.

 

This will work.....so will startin the bike with the head pipes on it and allowing the metal to "expand" a bit---probably not the best practice though....I'd go with the WD or th PB....

 

Do yourself a favor and take that slip on to your local muffler shop and have them open it up with their hydraulic bender.

TRUST ME, I've been there with the exact same set up. Don't bother buying that harbor freight pipe expander. It's a pos!

 

Let me clarify, take it to the local muffler shop and have them open it up with their hydraulic expander. Mine had the expander on the other end of the bender.

 

Go buy a cheap pipe expander, you will use it every time you take a muffler off.

Mark