need instructions for crossover remove

phenrichs · 06-26-2009, 01:52 PM

I got to see a couple bikes in Custer with the left side cleaned up and that is the way I want to go. I remember a while back someone posted some instructions on doing the crossover removal without destroying it. Anyone have a link for that?

Thanks

cactusjack · 06-26-2009, 02:16 PM

I'm pretty sure you have to remove the throttle body and intake manifold to get the crossover tube out intact. That's a lot of work.

phenrichs · 06-26-2009, 02:42 PM

Damn I thought somebody unhooked it and managed to get it out the left side in one piece?

Awe hell maybe I'll just cut it.

**ringadingh** · 06-26-2009, 02:46 PM

Check Gadgets sight , I think there is some info there about that.

macmac · 06-26-2009, 07:38 PM

There is two ways.... One way is just lots of work and the other is to cut it.

IF you cut it on the left side, about 5/8" back from the flanges, or after the swelling for the screws holes, maybe one day it can be reinstalled and plastic welded.

So if you cut it, cut it there. use a dremel and a fiberglass re-enforced whizz wheel.

Then with a dead blow mallet and a 1" dowel of wood drive that puppy out the right side after you remove all the stuff in the wy over there...

2 maybe 3 blows should do it. I would do it! I have thrice.. My 01, my 06, and another guys bike..

**jestephens** · 06-27-2009, 02:12 AM

I concur with my learned colleagues . . . did it with a hack-saw. I could not find a way to do it with out destroying the crossover. I decided it was a point of no return and began hacking away at it. ;0)

macmac · 06-27-2009, 07:51 AM

Sometimes i don't understand that not everyone has the tooling I have.. A dremel is alittle pricey too.

But most people have a coping saw, and most of these saws can have the blade mounted at 90 degrees to the frame, and should work. Just pull the cross over tube to the left side, where the stock air filter was, so far as you can and wedge it there to reduce wiggle.

Don't get in a hurry, and take yer time, or something will get bashed.

06-26-2009, 01:52 PM	#1
phenrichs Sr. Member Join Date: Jun 2008 Location: Sioux Falls, SD Posts: 2,498	need instructions for crossover remove I got to see a couple bikes in Custer with the left side cleaned up and that is the way I want to go. I remember a while back someone posted some instructions on doing the crossover removal without destroying it. Anyone have a link for that? Thanks Login or Register to Remove Ads
	0

06-26-2009, 02:16 PM	#2
cactusjack Mega-Contributor Join Date: Sep 2007 Location: Where it doesn't snow...ever! Posts: 21,926	need instructions for crossover remove I'm pretty sure you have to remove the throttle body and intake manifold to get the crossover tube out intact. That's a lot of work. __________________ Scott "Cactusjack" Hanks VBA #00105 H.O.G. #4250060 2011 H-D Ultra Limited 103ci :: 2011 HD Electra Glide Ultra Limited w/Stage 1 :: Rallies: Mesquite '08\|Custer '09\|Cortez '10\|Crescent City '11\|Kanab '12\|Antlers '12\|Estes Park '13\|Antlers '13\|Orofino '14\|The Dalles '17
	0

06-26-2009, 02:42 PM	#3
phenrichs Sr. Member Join Date: Jun 2008 Location: Sioux Falls, SD Posts: 2,498	need instructions for crossover remove Damn I thought somebody unhooked it and managed to get it out the left side in one piece? Awe hell maybe I'll just cut it.
	0

06-26-2009, 02:46 PM	#4
ringadingh Join Date: Aug 2007 Location: Newmarket Ontario Canada Posts: 35,387	need instructions for crossover remove Check Gadgets sight , I think there is some info there about that. __________________ 2002 Nomad aka Bountyhunter VBA #27 VROC #18951
	0

06-26-2009, 07:38 PM	#5
macmac Sr. Contributor Join Date: Apr 2008 Location: Tamworth New Hampster 06 1600 Posts: 12,484	need instructions for crossover remove There is two ways.... One way is just lots of work and the other is to cut it. IF you cut it on the left side, about 5/8" back from the flanges, or after the swelling for the screws holes, maybe one day it can be reinstalled and plastic welded. So if you cut it, cut it there. use a dremel and a fiberglass re-enforced whizz wheel. Then with a dead blow mallet and a 1" dowel of wood drive that puppy out the right side after you remove all the stuff in the wy over there... 2 maybe 3 blows should do it. I would do it! I have thrice.. My 01, my 06, and another guys bike.. __________________ 06 1600 Nomad Just call me Mac molon labe come and get it Login or Register to Remove Ads
	0

06-27-2009, 02:12 AM	#6
jestephens Join Date: Jan 2009 Location: Fairview Heights, IL (StLouis) Posts: 1,601	need instructions for crossover remove I concur with my learned colleagues . . . did it with a hack-saw. I could not find a way to do it with out destroying the crossover. I decided it was a point of no return and began hacking away at it. ;0) __________________ Jay Stephens, Former National Vice President (2013-2015) 2006 Yamaha FJR1300 formerly 2011 Vaquero- Black formerly 2005 Nomad - black/silver
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06-27-2009, 07:51 AM	#7
macmac Sr. Contributor Join Date: Apr 2008 Location: Tamworth New Hampster 06 1600 Posts: 12,484	need instructions for crossover remove Sometimes i don't understand that not everyone has the tooling I have.. A dremel is alittle pricey too. But most people have a coping saw, and most of these saws can have the blade mounted at 90 degrees to the frame, and should work. Just pull the cross over tube to the left side, where the stock air filter was, so far as you can and wedge it there to reduce wiggle. Don't get in a hurry, and take yer time, or something will get bashed. __________________ 06 1600 Nomad Just call me Mac molon labe come and get it
	0

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