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Discussion Starter #1
Well after my 2nd go around with the cylinder studs I got the bike together and running, so today is the 1st long distance test ride.
I did take the bike for a short ride yesterday (about 10 miles) but it started to rain so the ride was cut short.

I started the repair on Sunday and finished it up Monday, it took me a bit longer to do the repair then usual but it was DAMN HOT outside so I took a few more breaks .
I only found 1 cylinder stud that was pulled (front cylinder behind the spark plug) I did check the torque on all the cylinder studs BEFORE I tore the top end down and all the other 7 cylinder studs torque settings were right where they were suppose to be.
I only had to take the jug off the front cylinder so that cut my repair time down a little, I did replace the .030 Cometic head gaskets with .040 Cometic head gaskets so I did have to tear the head off the rear cylinder.

So I am crossing my fingers and hoping for the best and if the bike runs good then it is off to the dyno for a good tune.
 

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Discussion Starter #7
Why did you go back to a .040 head gasket? Trying to lower the compression?
The bike ran great so far. I do have a rattle in my right muffler which is the exhaust for the front cylinder, I can only hear the rattle after the bike warms up and only on decel when the engine is around 2000 rpm.
I am checking it out more today but I believe the baffle is lose, I already checked the bolts and heat shields and everything is tight.
The V&H monster rounds I have are only 4 or 5 month old and V&H warranty is only 90 days so I am not too happy about having a problem with these new mufflers.
I went with the .040 head gaskets because it was what the local bike shop had in stock, I would have had to order a .030 head gasket, there isn't that much difference in compression between the two and you wouldn't even notice the difference. The stock HD head gaskets are .045.
 

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Discussion Starter #8
I got a hold of V&H and they told me to remove the baffle and take some pics and they may or may not warranty the baffle.
The tech support guy told me to remove the 2 screw on the bottom of the end cap and pull the baffle out. I can tell you that the baffles on the monster rounds just don't come out, it took over 4 hours to remove the baffle and the baffle was destroyed in the process.
The main problem was the fiberglass packing inside the baffle, as you pulled the baffle out the packing would bunch up and lock the baffle up tight as a drum. After pulling and tapping and tugging the end of the baffle came off the expanded metal screen so now I had 1/2 the baffle in my hand and the other 1/2 stuck in the exhaust. I had to spend a lot of time digging out the packing but I did get the rest of the baffle out.
The good news is V&H is going to warranty the baffle, the bad news is that they have to make a baffle and it will take 3 weeks to get the replacement baffle.
I put the 1/2 of the baffle that broke off the screen back in the exhaust so I will have some back pressure and still ride the bike but the exhaust isn't equal now so I have to reschedule the dyno tune.
 
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