D&D PERFORNANCE EXHAUST
                 

 When my son Dale got his 2008 Harley FLHTCU it did not take him long to ask me what he could do to the exhaust system.
 My answer was a lot. You need to be more specific what you want to accomplish with the change as different systems provide different results.   What we came up with was to use a true dual system so the appearance of the motorcycle would not change drastically.
  The D&D Duelie pipes (part 516-22D) were chosen because they looked good and would enhance performance by giving the rear cylinder its own pipe providing a true dual exhaust. Adding a set of D&D 3 ½ inch slash cut mufflers (part 408-12S) would produce a good sound without being offensive.
 It wasn’t until I actually received the exhaust that I saw the quality of construction, heavy gauge of the metal, with oxygen sensor bungs welded in place, flawless chrome, and heat shields already installed that I really became impressed.
 I started off by removing the saddlebags so everything was easy to get at. Next was to remove the factory heat shield with a 5/16-1/4 drive socket (a common screwdriver may also be used)
 Using a 9/16” socket I loosened the clamps at the mufflers and sprayed the joints with PB Blaster penetrating oil. While it was working I went to the rear of the muffler and used a 1/2 inch socket to remove the bolts there. The muffler was removed by moving it up and down while pulling on it.
 I disconnected the wiring for the Oxygen Sensors but opted not to remove them from the pipe until I had it off.
 From the left side of the motorcycle using a 3/8 ball end allen with a extension I removed the right floorboard where the brackets joined the frame.
Removing the clamp on the pipe by the transmission and the two nuts holding the pipe to the head it came off easily.
 The pipe on the left side was removed in the same manner. It should be noted that the bracket tab on the rear exhaust support bracket is also removed. There was no need to remove the exhaust flange off the old pipes as the new pipes have them on already.
 With the factory system removed the exhaust gaskets were replaced in the head and the Oxygen Sensors were removed from factory pipes and installed into the new ones. A small amount of Anti-Seize was applied to the threads with care taken Not To Get Any On The Sensor! Torque to 30-44 Foot lbs.
 The right side pipe was fitted to the head. Starting the nuts by hand and then using a ½ inch ¼ drive socket the top nut tightened to 18 inch lbs.  I was pleasantly surprised to find a cut out in the heat shield for the bottom nut that allowed the socket to fit with out the problems that I have had with other systems. The bracket welded to the pipe fit the bracket on the transmission with out any shimming. Clearances were checked and the bottom nut on flange tightened to 100-120 inch lbs. followed by the top one to the same specifications. The muffler slid in with ease and could be felt to bottom out on pipe. The clamp was tightened enough to hold muffler in place as the two black spacers provided in kit were installed at the saddle bag hanger. The bolts were torqued to 96-144 inch lbs while alternating tightening. The muffler clamp was Not fully tightened at this time.
 Going to the left side of the motorcycle the rear pipe was installed in the same manner as the front. I do use a piece of folded cardboard to hold the pipe in position until I get it set where I want it. Once everything is in place all fasteners are tightened.
 From the rear of the motorcycle the mufflers are positioned so they are even and clamps fully tightened.
 While I was connecting the wires for the Oxygen Sensors and re-installing the floorboard with the spacers provide in the kit my helper installed the covers and saddle bags. A final check was made that everything was installed and tightened properly.
  Even though I use gloves while doing the job the pipes were rubbed clean just to make sure there was not anything on them that would leave a stain when the pipes got hot.
 I cure the chrome by running the engine at idle speed for about one minute. Let motorcycle cool and repeat 3-4 times.
 Depending on your motorcycle you may have to make some adjustments to your fuel system. I rode the motorcycle and was quite happy with how it sounded and performed. I also did a sparkplug color check and everything got a thumbs up!
 I mentioned to my helper that I do not remember the last time a job went so well and everything fit like it was suppose to. He had recently installed another brand of exhaust on his bike and said it was a lot of work to get it to fit correctly.
 To keep the pipes clean, wipe down with Rubbing Alcohol and shine with Glass Cleaner. DO NOT USE HARSH ABRASIVES!
 When I brought the bike to Dale and told him to take it for a ride the Big Smile on his face told me we made the right choice with a D&D exhaust.
 For more information on D&D and their products check their website http://www.danddexhaust.com/ or contact their office at D&D Performance Enterprises, 2923 Edith Lane, Fort Worth, Texas, 76117. Phone 817-834-8961

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