D&D fat cat install

Discussion in 'Engine, Fuel and Exhaust' started by marknett, Jan 10, 2013.

  1. marknett

    marknett Active Member

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    My D&D fat cat arived today for my 2012 dyna switchback . I decided to document the install as I go .. Yes complete with pictures. :newsmile011:
     
  2. marknett

    marknett Active Member

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    First a little background . The bike is running factory header with vance and hines twin slash slipon .





    first I removed the twinslash from the header as seen in the 2nd pic
     

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  3. marknett

    marknett Active Member

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    next I had to remove the right side driver footboard
    Did not need to remove linkage , just unbolt the 4 torx bolts (t-45) and let it rest on the ground.I sprayed the exhaust flange bolts with penetrating oil when I started .You may notice the bluing in the 2nd pic. I have a gen3 fuel controller on the bike , but with the cat installed in the factory header , your gonna get instant bluing. I removed the chrome covers because it was easier to remove the header with them out of the way. To remove the header you remove the 4 flange nuts (1/2" socket) and there is a bolt under the bottom of the header (9/16 " socket) .. once it's loose you can remove the bung air sensors . I used a small cresent for this
     

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  4. marknett

    marknett Active Member

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    Now we have the exhaust off . we now need to remove the factory mount because the fat cat comes with it's own mount.Installing there mount is pretty straight forward although you are not using the factory holes.we need to remove 2 of the transmission cover plate (not on the chrome cover on the black casing cover) for installation. we do use 1 original mount hole with a provided spacer behind the bolt. Don't want to over torque here. We need to remove the old crush style exhaust gaskets from the front and rear cylinder now . Now we can install the header .Don't forget to screw in the bung sensors now before mounting the header. The factory header used a bevel style header and crush style gaskets . The fat cat is a straight style with a compression style metal gaskets . insert these in the front and rear cylinders now. Using the bottom factory mount and bolt to help hold it in place , I then got my flanges started and put the 5/16" nuts on loosely .We don't want to tighten anything on the exhaust yet just get into place and snug.
     

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  5. marknett

    marknett Active Member

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    Now we can install the muffler by sliding it into place and letting the (2) 3/8 "
    studs to go into the holes in the new mounting bracket . D&D sent 5/16 " nuts for this but we had the correct 3/8 nuts available. now that the system is all in place and snug, we can start tightening everything up . Start at the heads and tightened to factory specs and work yout way back toward the muffler . Keep everything aligned and straight as you go. Once this is complete we need to install the footboard back on. D&D sent 2 spacer plates to shim this out for clearance and you reuse the factory bolts .The job took a couple of hours to complete with a few aggravating steps but all in all an easy job . I will also try to include sme sound bytes before and after. :D
     

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  6. mat 60

    mat 60 Senior Member

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    Nice job marknett. Good looking Dyna. Now for the sound test.:)
     
  7. Jack Klarich

    Jack Klarich Expert Member

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    Nice job and good pictures, cant wait to hear it:D