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  1. #1
    Iron Butt smitty901's Avatar

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    2017 RGU Blackhills gold and black-96 FB Black with sidecar
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    2-1-2 header install

    has requested here it is.

    2-1-2 header install. remove bags front right foot board and set aside remove right exhaust pipe and set it aside. Leave cross over attached to the frame. Remove heat shields a 1/4 in drive with socket and short extension works better than a screwdriver IMO. Set where they won't get damaged. Remove side cover and unplug 02 sensors front and rear are different colors. feed the through so they hang lose. Do not try to remove them with stock header still in the bike. Loosen and the crossover clap on the right side. Carefully remove flange nuts 1/4 drive with extension worked for me cover you lowers Remove the carnage bolt that hold header in place . carefully wiggle the header out ,you may need to tap it with rubber hammer. Lay it down now remover 02 sensors. Install wide band plugs in new headers. Some reuse stock gaskets some replace them with flat one 50-50 works both ways I prefer the flat ones. Remove flange from stock header. Place on new 2-1-2. Now the fun starts. Put your anit seize on studs. Go back to the cross over pipe remove gasket and open up the pipe a bit with an expander. If you bypass this you end up fighting to get the pipe in and damage the gasket. now install 02 sensors allow wires to hang free, Make sure exhaust port gaskets are in and start lining it up. Fuel moto has instruction on tightening it up. It takes a bit of effort the get thing all lined up do not over tighten exhaust studs. You may need to loosen the mounts for Cross over and left pipe to line it up a bit. Once cross over in seated correctly you can tighten header down. Don't over do it. Line up exhaust pipes and clamp them down. plug 02 sensors back in. follow Fuel motos instruction for running it to heat up pipes coating then allow to cool. install heat shield with a lose fit tighten each as you line them up. It is a good idea to replace the hose clamps with new 100% SS ones . Enjoy the new headers.

    Boards out of the way
    Click here to enlarge

    Cross over
    Click here to enlarge

    Header off ready to remove 02
    Click here to enlarge

    ready for heat shields
    Click here to enlarge


    Good luck with it
    Dianne Feinstein:
    "All vets are mentally ill in some way and government should prevent them from owning firearms."

  2. #2
    Ride Captain papa'sSG's Avatar

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    Jan 2013
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    Sioux Falls SD
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    2008 Street Glide Anniversary Edition 2015 EG Ultra Classic Low
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    Great pics smitty, thanks much.


    In the interest of further explanation I found this youtube video for Rinehart pipe and mufflers and pipe. Concept is the same and this guy did it in 7 minutes LOL.


    https://www.youtube.com/watch?v=DmWALJFeIfY

  3. #3
    New Member Liaison Tom's Avatar

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    Looking good
    May I be "the least in the household of God."...

  4. #4
    Iron Butt smitty901's Avatar

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    It does not take pong. You do want to take your time to avoid any exhaust leaks it is a pain to go back and find them
    Dianne Feinstein:
    "All vets are mentally ill in some way and government should prevent them from owning firearms."

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