Service Manuals Not Very Helpful Here

[Valkorado]

Grrr.  Taking a break, before I break something.  Since I got her, Ruby has had some issues.  She's got a leak in her left exhaust somewhere inside where the headers meet the can.  She was getting roasty around that area, the fan was kicking on at 200° and running too much and the exhaust was pinging and popping from that area for a good ten minutes after I'd shut her down.

Decided it was time to bite the bullet and get a replacement exhaust.  Not easy to find Interstate exhausts in decent shape.  Finally found one that looked pretty good on eBay.  Not cheap after shipping.  Arrived this morning, headers a bit more blued than the pictures showed but not too bad.  It should work, but...

Old pipe came off easy enough.  I can't get the new-used sucker on!  It seems straight enough but getting that pipe to line up is driving me nuts!!!  I am trying to tackle the job alone, and can't see what's going on in the front from the back and vise-versa.  The service manuals make it sound easy-peasy.  Not my experience so far.  Any tips or pointers?  The header bolt threads are already a slight bit scraped (but still ok) from trial and error.  I don't want to strip 'em out.

The bike does have Mick-O-Pegs installed that make things more interesting, but I am finagling the headers around it.  Just can't seem to get the exhaust ports to line up over the six bolts.  I've  got the  pipe "stuck" a few times already, which makes me cuss like a sailor.  I manage to get it unstuck, but still can't get those pipes on flush front and back.  I know once I do get it lined up to carefully tighten the front six bolts first, then the rear two.  I just can't seem to get both sides lined up...

Driving me nuts!  

Making matters worse, while taking a breather and looking around with a super bright LED headlight, I see the octopus is not properly seated.  Not good or fun.  I recently got done doing that project on the Silver Bullet, not enjoyable.  I guess I'll be "going in" for that on Ruby too -- after I figure out the exhaust pipe.

BTW, I did pick out the old exhaust gaskets and have already set the new ones so that's not the problem.  

Also, re: the Mick-O-Pegs.  It might be easier to get the exhaust pipe on if I remove that left Mick-O-Peg.  I've removed the only (2) bolts on the backside of the mount, but can't get the halves to break apart.  Is there a trick to removing these?

updated for afterthoughts

[luftkoph]

Loosen the 2 bolts on the hanger that the passenger and exhaust mount to that gives some wiggle room, also removing the engine bars might help with maneuvering

[Valkorado]

Loosen the 2 bolts on the hanger that the passenger and exhaust mount to that gives some wiggle room, also removing the engine bars might help with maneuvering

I'll give the hanger idea a try.  Not sure I'm ready to remove the bars at this point.  I'm trying to get stuff on, not take more off.   

[rug_burn]

I think if the exhaust is getting that hot, you've probably got a cylinder or a few running real lean.   You may want to check that out

[Valkorado]

Got it on, the problem was at the rear bar/saddlebag mount.  I'm thinking when I was rear ended it knocked the alignment out out of whack just enough to make it very difficult getting the two exhaust mount bolts on back there.  I loosened some bolts and made it work.  Oh yeah, I also removed the metal saddlebag support plate and the front and rear chromed tins from the pipe, which helped me get everything lined up.  Popped right on after all that.  Thanks luftkoph.

NOW on to the damn octopus -- in a day or two.  rug-burn, do you think that octopus being unseated could also be contributing to the hot running?

Thanks again.

[rug_burn]

     By 'octopus' do you mean one of those 6 into 1 manifolds of hoses under the gas tank?  One is vapor, the other the fuel drain for the carbs.   Those probably wouldn't cause it to run lean, I don't think.
    But your situation sounds like what mine was like before I went through and rebuilt the carbs.   How does it sound at idle?  if its not real smooth, could be an indicator of fuel gunkage to the carbs.   Another thing that's easy to check is to pull out the diaphragms and check to ensure the needles are clean and free of varnish.   
      My bike sat one time for about a year 'cause I was putting off fixing the clutch plate rivet thing.  The gas went bad and dried out, and the needles got a layer of varnish on them.   I scratched it off with my thumbnail, then carefully cleaned out the main jets below with the right size drill bit (.101" is real close) holding it in a pin vise, and doing the job by hand.  It helped a little maybe at certain times, but I still ended up rebuilding all the carbs.

[Valkorado]

I was referring to the airbox, it's not properly seated to the carbs.  I'm going in soon to fix it, after a short hiatus.  I've learned my lesson that when I purchase a used bike, I should go over everything from top to bottom and not leave anything to chance.

Challenging since I'm a klutzy, and unskilled wrench.  I've learned much since owning Valkyries, but I'm not sure I want to learn much more the hard way.

[Jims99]

I can run lean if the airbox is not connected right. If all the boots are not seated properly, it can cause an air leak. Use a small mirror if you need to see backsides better. Will make a difference.

[Valkorado]

I can run lean if the airbox is not connected right. If all the boots are not seated properly, it can cause an air leak. Use a small mirror if you need to see backsides better. Will make a difference.

Have one for that purpose.  Will do.

[gordonv]

a mirror and dental/long reach type pick would be helpful, along with some lube, alcohol evaporates and makes rubber slippery.

Before you do it, did you inspect/replace your intake runner o-rings on the block?

[Valkorado]

a mirror and dental/long reach type pick would be helpful, along with some lube, alcohol evaporates and makes rubber slippery.

Before you do it, did you inspect/replace your intake runner o-rings on the block?

Yup, got the runners last year with viton rings.