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Thread: Interesting weekend

  1. #1
    Senior Member wally's Avatar
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    On my way to a men's camp on Friday evening I heard the familiar exhaust rattle which normally happens when that stupid front mounting bolt shears off...

    The rattling lasts till about 3000 RPM and then quiets down. This however lasted the whole rev range.

    Pulled over and saw the new front strap had snapped!!! Exactly where the old one did!


    Torqued and installed correctly. I mean, seriously!!! Got some wire and temp fixed it:


    At the venue (on a farm) the owner turns out to be an engineer.

    Pulled into his garage, pulled off exhaust, welded the strap with his fancy schmancy welder with stainless rod.
    Made a little spacer to compensate for the loosness/play in the mount's bushings.

    Then we saw this on the bottom of the header:


    Completely worn out from heat - anyone else seen/experience this?

    I think this is the reason why the torca clamp doesn't seal properly, which in turn places stress on the front muffler strap and mount?

    Also saw my exhaust servo cable is badly frayed and might snap soon.

    Now, on the 08 Uly, what are my options?
    1. get new cable (easy to install?)
    2. Can I unhook on the exhaust and bypass with Tunerpro RT as with ECMSpy?
    3. Emulator?

    If I get this all sorted then she is A-OK again!

  2. #2
    Senior Member d_adams's Avatar
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    Completely worn out from heat
    Ah, nope. That's from vibration and movement.

  3. #3
    Senior Member wally's Avatar
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    mmmm, thanx!

    Going to ask the guys that fixed my 02 sensor mount if he can cut that out and weld a new ring in there.

    I really need to get this front mount issue sorted!
    I have tried everything!

    On the plus side, got my reflector strip for top case from local Hepco Becker supplier and fitted it this afternoon.
    Looks like new!

    New one fitted:


    Old broken one:

  4. #4
    Senior Member d_adams's Avatar
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    Just from looking at the header, I'd say you have a bad vibration problem. Have you swapped out the isolators for new ones? It's a pita just to change those out, so if you have other stuff to do while the frame is off, that would be the time to do it.

  5. #5
    Senior Member wally's Avatar
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    Nope and I probably won't get to it this year. It is my daily driver, so I need it every day.

    Plan is to drop motor next year, chic and replace gaskets, etc.

    This year will be shocks and bearings.

  6. #6
    Senior Member d_adams's Avatar
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    Pulling the frame doesn't take all that long, it can easily be done in a day if you get after it.

  7. #7
    Senior Member wally's Avatar
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    What would all be needed for the replacement?

    I will have to check that my HD dealer has supplies in stock, otherwise I have to import.

    Is there a write-up somewhere perhaps on how to replace the isolators?

    Thanx!

  8. #8
    Senior Member d_adams's Avatar
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    I'm sure there is, the front isolator is about $70 I think. I got the threaded insert while I was at it. Don't remember the cost of the rear but it wasn't astronomical or anything. I built a small frame to support the engine while it was apart that bolted to the front and rear of the cases. It can be done with a regular motorcycle jack and rear wheel stand though, it just needs to be relatively stable. Having a 2nd body to help lift the frame off helps, I left the front end intact on mine so it was a little heavier that way.


  9. #9
    Senior Member lunaticfringe's Avatar
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    get new cable (easy to install?)
    yes. very very tempermental to route it correctly but with patience can be done.

  10. #10
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    Do you have a ECM cable to hook up to the bike? I can walk you through how to turn off the muffler valve with tuning.



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