Wiktor Wise
Removing the exhaust from a Harley Electra Glide can be a challenging task. While it is possible to do it yourself, it is important to have the right tools and knowledge to avoid any damage to the motorcycle. In this discussion, we will explore the steps and techniques for safely removing the exhaust from a Harley Electra Glide, including the tools required, common challenges such as tightening the lead exhaust stud and removing the muffler from the header, and potential risks. We will also cover the different types of exhaust systems found on these motorcycles, such as the mufflers and heat shields, and provide insights into the Harley-Davidson community's experiences and recommendations for a successful exhaust removal process.
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What You'll Learn
Removing the muffler from the header
First, remove the saddlebags and heat shields. This will give you better access to the muffler and header. Next, loosen the clamps on both mufflers. You can use a wrench or your hand to loosen them, but be careful not to overtighten or strip the threads. If the clamps are difficult to loosen, you can try spraying them with a penetrating lubricant like PB Blaster or WD-40. Allow the lubricant to soak for a few minutes before attempting to loosen the clamps again.
Once the clamps are loose, you can begin to twist the mufflers off the pipes. It may be necessary to gently move the mufflers side to side and up and down to release the clamp force. Be careful not to use excessive force, as this can damage the pipes or mufflers. With the mufflers removed, you can now access the header.
Before removing the header, it is important to clean the area and inspect for any damage. If there is any rust or corrosion, it may be necessary to replace the header or seek professional help. Once you are satisfied that the header is in good condition, you can proceed to the next step.
Finally, to remove the header, you will need to loosen and remove the header bolts. Do this carefully, as you do not want to strip the threads or break the bolts. With the bolts removed, you can now lift the header away from the engine. Be careful not to damage any nearby components or wires.
It is important to note that this process may vary slightly depending on the year and model of your Harley Electra Glide. Always refer to a service manual or seek advice from a qualified mechanic if you are unsure about any steps or procedures.
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Using WD40 to loosen bolts
Removing the exhaust from a Harley Electra Glide can be a tricky process. While it is not necessary to remove the exhaust to install a new cover, some maintenance procedures may require it.
One of the most challenging aspects of this task is dealing with the bolts, which can be difficult to loosen and remove. Here is a detailed guide on using WD40 to loosen bolts when removing the exhaust from a Harley Electra Glide:
Prepare the Necessary Tools and Materials
Before starting the process of removing the exhaust, it is important to gather the required tools and materials. These include WD40, a wrench, and a service manual specific to your Harley Electra Glide model. Having these items on hand will make the process smoother and help prevent any unnecessary delays.
Apply WD40 to the Bolts
Once you have identified the bolts that need to be removed, the next step is to apply WD40 to them. WD40 is a water-displacing spray that is commonly used to loosen rusted or stuck parts. Spray a generous amount of WD40 directly onto the bolts and let it soak. The longer you allow it to soak, the more effective it will be in loosening the bolts. It is recommended to let it sit for a few minutes, but for extremely tight bolts, you may consider letting it soak overnight.
Attempt to Loosen the Bolts
After the WD40 has had sufficient time to work its way into the threads of the bolts, it's time to try loosening them. Use a wrench that fits securely over the bolt heads and apply force in the counterclockwise direction to try to loosen them. It may require significant force, especially if the bolts are tightly fastened. If the bolts still won't budge, you can try tapping the wrench with a hammer to deliver a sharp force that might break the bond.
Alternative Techniques
In some cases, the bolts may still prove stubborn even after using WD40. If this happens, there are a few alternative techniques you can try. One suggestion is to use a breaker bar or a cheater bar/pipe, which are designed to provide additional force for particularly tight bolts. You can also try placing the saw in a vice grip and using a fitting wrench with an extension rod as a force multiplier.
Final Thoughts
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Tightening the lead exhaust stud
When it comes to removing the exhaust from a Harley Electra Glide, one of the most challenging aspects is tightening the lead exhaust stud. This process requires patience and precision, and it is essential to have a service manual to guide you through the steps.
To begin tightening the lead exhaust stud, it is recommended to use a product like PB Blaster or WD40. Spray the product generously onto the bolts and allow them to soak for several minutes. This step helps to loosen any rust or debris that may be causing the bolt to stick. It is important to be cautious during this process, as over-tightening can lead to snapped bolts.
Once the bolts have been adequately loosened, it's time to start the tightening process. First, make sure you have the correct torque settings for your Harley Electra Glide model. Refer to the service manual for the specified torque range and adjust your torque wrench accordingly. It is crucial to tighten the bolts within the recommended range to avoid over-tightening, which can cause damage.
As you tighten the lead exhaust stud, pay attention to any resistance or unusual tightness. If you encounter tight spots, back the bolt out slightly and wait before continuing. This pause helps prevent the bolt from getting too hot and potentially snapping. Take your time and work gradually, making sure the bolt is secure without applying excessive force.
Finally, it is important to note that you may not need to remove the entire exhaust system to access the lead exhaust stud. By removing the hanger bolts under the saddle bag and the bolt from the brace at the lower center of the exhaust, you can gain enough access to tighten the lead exhaust stud and retighten the header bolts. Remember to take your time, work carefully, and refer to the service manual for any specific instructions or torque settings related to your Harley Electra Glide model.
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Disconnecting the left-side pipe
Prepare the Workspace and Gather Tools:
Before beginning, ensure you have a suitable workspace with adequate lighting and a flat, stable surface to place your tools and parts. Gather all the necessary tools, including a service manual (highly recommended), wrenches, screwdrivers, and penetrating lubricant (such as WD-40 or PB Blaster). Having a clean workspace and organizing your tools will make the process more efficient and help you avoid losing any small parts.
Loosen the Exhaust Stud and Hanger Bolts:
Locate the exhaust stud and hanger bolts under the saddle bag on the left side of the bike. Spray the bolts with your chosen penetrating lubricant and allow it to soak for a few minutes. This will help loosen any rust or corrosion and make the bolts easier to remove. Once they are loosened, you can proceed to the next step.
Disconnect the Left-Side Pipe:
Using the appropriate-sized wrench, begin by loosening the header bolts on the left-side pipe. It is important not to remove these bolts completely just yet. You should only loosen them enough to be able to move and lift the exhaust pipe. After loosening the header bolts, you can now disconnect the left-side pipe. This may require some wiggling and maneuvering, as the pipe may be snugly fitted. Take your time and be gentle to avoid putting excessive force on any components.
Lift and Remove the Exhaust:
Once the left-side pipe is disconnected, reach down and carefully lift the exhaust pipe upwards and outwards. You may need to gently rock or wiggle the pipe to free it completely from its housing. Take caution not to scratch or damage any nearby components during this process. Continue lifting and adjusting the pipe until you have enough clearance to access and replace the exhaust cover.
Reinstall and Secure the Exhaust:
With the exhaust pipe lifted and the cover accessible, you can now replace the exhaust cover or perform any other necessary maintenance. Once you have completed the required tasks, carefully reposition the exhaust pipe back into its original location. Ensure that it is securely seated and aligned correctly. Finally, tighten the header bolts, hanger bolts, and any other fasteners that you previously loosened or removed.
Remember to take your time, work methodically, and refer to a service manual if needed. By following these steps, you can successfully disconnect and reinstall the left-side pipe of your Harley Electra Glide exhaust.
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Using a service manual
Removing the exhaust from a Harley Electra Glide can be done by following the steps outlined in a service manual. Here is a detailed guide based on the service manual instructions:
First, remove the hanger bolts located under the saddle bag. These bolts secure the exhaust in place, so removing them will allow you to access the exhaust and begin the removal process. Next, take out the bolt from the brace at the lower centre of your exhaust. This will further loosen the exhaust and make it easier to work with.
It is important to note that you should not completely remove the header bolts. Simply loosen them, as they will need to be reinstalled later. If your Harley Electra Glide has dual exhaust, you will need to disconnect the left-side pipe. This is a crucial step to gain better access to the exhaust system. Once the bolts and connections are loosened, reach down and carefully lift the exhaust up and out. Take your time with this step to avoid any damage to the surrounding components.
At this point, you should be able to remove the exhaust cover and reinstall a new one if needed. After installing the new cover, carefully lower the exhaust back into place. Reinstall the hanger and brace bolts that were previously removed. Ensure that all bolts are tightened securely, especially the header bolts.
Finally, take your time to inspect your work and ensure that all connections are secure and properly tightened. Consult the service manual for torque specifications and any additional reinstallation notes. Following these steps from the service manual will help ensure a safe and successful exhaust removal and installation process for your Harley Electra Glide.
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Frequently asked questions
First, remove the hanger bolts under the saddle bag. Then, take out the bolt from the brace at the lower center of your exhaust. Next, loosen the header bolts, but do not remove them. If you have duals, disconnect the left side pipe. Finally, lift the exhaust up and out.
Some people recommend using WD40 or PB Blaster on the bolts and letting them soak for a few minutes or overnight before removal.
Some people have found that the most difficult parts of the process are removing the muffler from the header and tightening the "lead" exhaust stud due to its tight fit.
