Restoration of Valkyrie Stock Exhaust

[carolinarider09]

2003 Valkyrie Standard, purchased new in 2003.  Sometime, in 2004, I installed the cobra six into six exhaust system, keeping the stock pipes in storage in the garage.

I would like to re-install the stock pipes.  Are there any issues I should be aware of in doing the re-install?

As I remember the first changeout, it was very simple and easy to do.  The only thing I need to check is to verify if I changed the needles on the carburetors. I should have the stock needles in storage so, if they were changed they will be there.

[firemedic309]

what you should do is keep the cobras on and sell me your old nasty stock system! LOL 

[Pete]

Just do NOT over tighten the exhaust nuts on the headers.
I would also get new exhaust seals.

[carolinarider09]

Thanks thats the kind of stuff I wanted to hear.

Got any idea of the torque requirements for the exhaust header bolts?

Ordering new seals today.

[Jess from VA]

Thanks thats the kind of stuff I wanted to hear.

Got any idea of the torque requirements for the exhaust header bolts?

Ordering new seals today.

Like 7 INCH pounds (maybe it's foot lbs, but it's not much).  I wouldn't touch a torque wench.  With new exhaust gaskets (the old might work), the idea is to just snug everything up.  Run and ride the bike to heat everything up, and snug again.  Maybe three times (and listening for leaks).  Trying to get it perfect on install is a good way to snap studs (often flush with the block, and a lot of fun to get out).

And a little anti seize on the studs/nuts is a good idea (and that also screws up torque wrenches).

And little quarter inch sockets are your friends. (both for fit into tight spaces, and feel for delicate work)

[carolinarider09]

Understood.  Have the 1/4 inch sockets and will use that and the anti-seize.

[semo97]

7 ft lbs. tighten as even as possible I go 6 lbs first then ride a little then 6.5 lbs and ride then the 7 lbs. I go slow doing this had to replace some snapped off studs. You may want to replace all the studs if you can get them all out.

[Chrisj CMA]

2003 Valkyrie Standard, purchased new in 2003.  Sometime, in 2004, I installed the cobra six into six exhaust system, keeping the stock pipes in storage in the garage.

I would like to re-install the stock pipes.  Are there any issues I should be aware of in doing the re-install?

As I remember the first changeout, it was very simple and easy to do.  The only thing I need to check is to verify if I changed the needles on the carburetors. I should have the stock needles in storage so, if they were changed they will be there.

You need six new exhaust gaskets

[carolinarider09]

7 ft lbs. tighten as even as possible I go 6 lbs first then ride a little then 6.5 lbs and ride then the 7 lbs. I go slow doing this had to replace some snapped off studs. You may want to replace all the studs if you can get them all out.

I have some special spray I mixed, found on another site, that I will use to prepare the nuts for removal.  I should have thought about that before.  Thanks for the reminder on the studs

[gordonv]

You need six new exhaust gaskets

Make sure that the old ones have been removed.

[Jess from VA]

You need six new exhaust gaskets

Make sure that the old ones have been removed.

Yep, after 20 years of high heat, they kind of hide up in there.  An ice pick can be helpful.

[old2soon]

`I have a 1/4" drive T-handle in my tool box that werx rather well WITHOUT using a torque wrench on the exhaust header nuts. On yer test ride and retightening of the exhaust header nuts have a spare or two exhaust header nuts with you on test ride.  Don't ask!  You WILL hear a rather sickening crack if you over torque.  NO-not an exhaust stud. Other bolts that I over torqued eons ago!  RIDE SAFE.

[John Schmidt]

I've never used a torque wrench on exhaust studs of any Valkyrie. Just use 1/4" drive socket/ratchet and an open end wrench(short one) if needed. Just take the nuts up snug, no more, then after a few rides snug again. Repeat! And yes....anti seize is your friend. 

[carolinarider09]

Darn I knew I should have waited to order the gaskets.  I could have easily added in a couple of nuts.  Oh well.   I will have to wait and see.

[carolinarider09]

Update:

Sprayed the special spray on the header bolt threads, waited 30 minutes (cleaned the OEM pipes) and then tried to turn the nuts.

All except one turned easily.  One was a bit stiff but moving it up and down and some more spray resolved that issue.

The hardest bolts were the larger ones that mount the pipes to the frame.  But they are all loose now.

I found, in my toolbox a 8mm 1/4 " drive universal socket.  I did not know I had it but must have gotten it when I did the conversion some 14 years ago.  Worked like a charm on those hard to reach nuts.

[Hooter]

I never tighten header nuts while the bike is hot. Ride it, let it cool down, then re-check the nuts. My 2cents.

[falconbrother]

I wish I could find a decent set of stock pipes.  I bought mine with the 4 in inch pipes and Lord have mercy they are loud. 

It's already been said but, those little exhaust studs are too small IMO.  Go easy on them.  Just enough torque is enough.  I think that nut is like a 10mm. 

[carolinarider09]

Now waiting on the new exhaust manifold gaskets to do the install.

The reason I am changing mine out is my wife "mentioned" that they were sort of loud.  

Short story as to why I put the cobras on.  

First trip to Key West in 2004 I was with two Harley riders and one guy on a Yamaha.  I remember starting the bike after a gas stop and break and I had to look down at the tach to make sure the engine was actually running.  The other bikes were so loud.

So, I figured, since i was riding mostly one up, I'd fix that with the Cobras. It worked and I have had many comments from those riding behind me how much the like the sound (not to loud but...) when going thru the mountains and I use the transmission to slow down for the next curve.  

 Now, later in life, my wife is riding with me more often, I figured it is time to change them back.  

[Smokinjoe-VRCCDS#0005]

I wish I could find a decent set of stock pipes.  I bought mine with the 4 in inch pipes and Lord have mercy they are loud.  

It's already been said but, those little exhaust studs are too small IMO.  Go easy on them.  Just enough torque is enough.  I think that nut is like a 10mm.  

I've got several sets not sure of condition on this set and can't get down to inspect right now ( took a chainsaw to my knee ) but if they are good I'd trade for ( 3 ) brand new Avon front tires . If interested I can check them out when I can. The Hondaline triple tips on these was toast I've already removed them but I have perfect Tourer or Interstate tips .
These pictures was taken the day I bought this bike its been in the dry since this day.

[carolinarider09]

Installation has been completed.  No major issues except that the cobras mount with bolts and the stock exhaust mounts with studs.  Could not find the original nuts in my stock of stuff.

Will have to find some replacements.  Had I know I could have ordered them when I got the gaskets.

Oh well.

Only one issue, slight ticking sound from the right front when engine is running.  I assume its an exhaust leak but cannot be sure.

Will monitor it and if any of you guys have any suggestions I'd be happy to hear them.

[Jess from VA]

I've replaced a few of the nice acorn nuts on the exhaust headers with two small regular nuts, sistered up snug together against backing off (with antiseize).  Hard to see without laying down on your back.

[carolinarider09]

UPDATE!

I replaced the nuts with some nylon lock nuts from Lowes.  Put about 60 miles on it yesterday and no issues.  The tick seems to go away after it warms up and is riden so it might be a lifter.

I forgot how nice the stock exhaust sounds.  Really a good sound.  And yes it is much quieter.

Re-tightend the exhaust manifold nuts twice after it had warmed up and then cooled down to room temp.

A couple would tighten or move a little, most did not.  Did not use a torque wrench.  So.....