Let’s hit it:
Tools Required:
½-inch combination wrench, open and box ends
5/16-inch combination wrench
9/16-inch combination wrench
3/8 ratchet, with 6-inch extension and ½-inch swivel socket
Flat-blade screwdriver
5/16 screwdriver-styled nut driver for the hose clamps
7/8-inch open-end wrench
Set of long massive Torx wrenches
JIMS exhaust gasket tool
JIMS has developed a new tool for ease of exhaust gasket seal installation on all Twin Cam or Evo heads. This new JIMS Exhaust Gasket Installer No. 788 will safely install exhaust gasket seal evenly and square without distorting the seal. Without the proper tool, you run the risk of developing an exhaust leak. This installer uses either the two exhaust stud flange nuts from the exhaust system or a JIMS No.33416-80 tool handle to install the seals.
JIMS Exhaust Gasket Seal Installer No. 788 is backed by a lifetime warranty and has an MSRP of $30.55. For more information visit JIMS on the web at www.jimsusa.com, find them on facebook, or call 805-482-6913.
Exhaust spring clip tool
Parts List:
2—3/8-inch 16X3/4-inch hex head bolts
2—3/8-inch flat washers
2—5/16-inch-18 x ½-inch bolts
2—5/16-inch flat washers
1—SP06-85 mounting plate
2—1/4-inch-20 Allen head bolts*
2—SPO4-29 removable baffles*
5-#24 hose clamps*
*Installed in pipe assembly
We started by removing the master cylinder pivot pin cotter key, then the Torx bolt holding the brake lever in place. We had to rock the lever out of harm’s way so the three 3/8-inch Torx footboard mounting screws could be removed and the foot board set safely out of the way.
Then we took off all the existing heat shields, but it’s good to note the position of the hose clamp fastener heads. We also noted how the flat blade screwdriver attempted to dance out of the slots on a regular basis, so we returned to the toolbox for the appropriate nut driver. It provided a much smoother, more secure operation.
Then we removed the four 5/16-inch flange nuts holding the pipes to the heads. These nuts are critical, and best reached without heat shield interference. We then removed the two 9/16-inch locking nuts holding the exhaust system mounting bracket to the frame. We did not need to remove the muffler clamps or mufflers, since the whole system is attached to the bracket, and we wouldn’t need it in the future. But there was a glitch–the passenger foot peg.
The foot peg fastener was a critical element used for attaching the massive muffler bracket to the frame. Once we removed the clip ring and the peg axle stud, we discovered a long 3/8 Torx Allen-styled bolt, and of course I didn’t have a Torx socket deep enough, or a long enough Torx to reach it. I was stuck, dead in the water. I called fellow land speed racer Tobey and caught him just leaving the Chowder Barge. I needed two things, and have no trust in our current junk auto-parts stores.
Tobey jumped on his sport bike and hit a major truck parts house—no luck. Then he jammed to one of these goofy auto parts stores and scored a set of massive Allen-styled Torx wrenches at O’Reilly’s. I didn’t know they made ‘em that big. Plus, we needed a rare 7/8-inch combination wrench to remove the 02 sensors. Very carefully, since most of these fasteners experience lotsa heat, I used a chemical spray, like Yield, on many threads to ease the pain of removal. That shit is amazing.
Once the peg was removed, the entire system popped free of the bike and we pulled it out just far enough to remove the costly 02 sensors with the big-ass 7/8-inch open-end wrench. Tobey saved the day, and kept the project moving.
We needed to remove the spring clips and flanges from the old system for use on the new Samson Hellraisers. I thought JIMS and a couple of other companies made a special tool for this application. It saves busted knuckles and lots of scratched chrome. Also note the flange positioning on the stock pipes. They slip onto the new pipes exactly the same way.
(Note: the snap rings may be lodged in the grove in the flange. Carefully pry the snap ring from the flange before removal.)
This is the time to remove the metal mesh exhaust gaskets if you wish to replace them. JIMS makes a very handy tool for installing new mesh exhaust pipe gaskets in the heads properly (above).
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This high-performance exhaust system has been designed and tuned to produce maximum horsepower, torque and awesome sound. Every exhaust manufactured by Samson is dyno tested before going into mass production for the ultimate in performance. The removable heat shields are pre-installed and the system is ready to bolt on right out of the box.
Additional Features and Benefits:
•O2 sensor ports accept O.E.M. / aftermarket sensors
•Available with massive 2 1/2″ one-piece full coverage removable heat shields
•Installer friendly (ready to install right out of the box)
•Mounting hardware included
•Improves gas mileage
•Two-stepped high-performance exhaust system
•Awesome deep tone
•Available for 2010-2012 Harley-Davidson dressers and Road Kings
•Available for 2012 Harley-Davidson Softails and Dynas
•Equipped with 1 3/4″ diameter x 10″ long removable baffles
•Available in Quad Chrome and Sinister Black ceramic finish (special request)
•MSRP-$699.95
*$629.95 (*If ordering directly off of the internet)
Kenny Price, founder and president of Samson Exhaust, is the “engineering genius” behind all of their products and holds many patents for high-performance exhaust systems for both the Harley-Davidson and metric cruiser markets. Samson Exhaust offers over 725 different exhausts to choose from, no matter what your riding situation.
Next, we installed the tough powder-coated mounting bracket, with the slots toward the front of the bike. It bolts right up. Samson recommends leaving everything loose during original installation.
We started with the front pipe, installing it to the front head with the stock ½-inch flange nuts loosely. (We wound the 02 sensor wires clockwise and installed the sensor in the pipe just before slipping it into place, since they are awkward to reach with the pipes fully in place.) At this point, we removed the heat shield, and the pipe was easy to install at the head. We then installed the 5/16 bolt through the bracket into the back of the pipe, where the appropriate tab was welded in place.
Next, we installed the rear pipe using the same procedure. This time, we installed the heat shield first. We slipped the hose clamps through the back of the heat shield and aimed the fastener head in the same direction as the stock installation. The Samson heat shields are designed specifically to cover as much of the base pipe as possible, and still give you access to the flange fasteners. But it’s still much more cumbersome to install the pipes with the heat shields in place.
We installed the rear pipe loose and checked the Hellraiser position. We started snugging the flange fasteners down just slightly, and then installed the front exhaust shield.
With everything installed loosely, we started to blue Loctite the fasteners, except the exhaust flange nuts at the heads and the 02 sensors. We started to move back and forth, tightening fasteners and checking alignment.
We carefully wiped the sharp-looking baffled system down, and then we pulled the bike off the lift. Samson recommends checking all the fasteners after 100 miles. We called the owner of the ’06 Fatboy, Victor, who started racing motorcycles when he was 15, and then in 2001 started racing offshore speedboats, 80 mph on the open ocean. He took second in his class in his rookie year. That same year, he took second in a class containing 21 boats in Key West, and hit 140 mph in the San Francisco Bay while piloting Renegade.
Victor’s no slouch, and likes the sound and performance of his new Hellraisers.
Samson Exhaust recently introduced a new 15% off, “discounted internet program” for all Bikernet.com members in order to help stimulate sales and to help during these hard economic times. Anyone ordering a set of Samson pipes direct from Samson and mentions Bikernet.com receives a 15% discount off the MSRP, plus free shipping!
Check out Samson Exhaust’s entire ‘12 product line at www.samsonusa.com or contact them directly at (888) 572-6766; Samson USA, 655 Tamarack Ave., Brea, CA 92821…email them at info@samsonusa.com. 
• Don’t forget about the Bikernet.com viewers special 15% DISCOUNT…order direct from Samson and mention Bikernet.com to qualify
Check out Samson Exhaust’s entire 2011 product line at www.samsonusa.com or contact them directly at (888) 572-6766; Samson USA, 655 Tamarack Ave., Brea, CA 92821…email them at info@samsonusa.com.
