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1981 GS850 headers very tight when installing Vance and Hines pipes

  • Thread starter Thread starter thewozza
  • Start date Start date
T

thewozza

Guest
I cleaned up the threads, installed studs and now I'd like to put on these 4 into 1 pipes.

But the header flange is really tight in the port, and I'd like advice on how to proceed.

Should I file down the irregularities on the pipes so it fits better?

Should I just muscle it in?

I called them last week but it sounded like the guy was following a script.
 
Do you mean the 4 pipes won't slip in nicely? Does any one pipe appear to be misaligned more than others? If so you could probably stick pry bar/ pipe in it and orient it better with some muscle.
 
thewozza said:
I cleaned up the threads, installed studs and now I'd like to put on these 4 into 1 pipes.

But the header flange is really tight in the port, and I'd like advice on how to proceed.

Should I file down the irregularities on the pipes so it fits better?

Should I just muscle it in?

I called them last week but it sounded like the guy was following a script.
Click to expand...

I had to file down some of the header flange to fit the V&H pipe to the sons 850. Don't force them in just give them a bit of a filing and all will be good.
 
thewozza said:
I called them last week but it sounded like the guy was following a script.
Click to expand...

So it turns out the fellah I talked to was just very chilled out. Once I took some pictures, made measurements we made good progress.

thewozza said:
Should I file down the irregularities on the pipes so it fits better?
Click to expand...

I sent the pictures to V&H and they agreed that the pipes were out of round, and that it was a manufacturing slipup. They offered to pay for both ways of shipping to repair this, or suggested I could take it to a machine shop to get them made round. So in theory a guy could probably grind them back, but I'm not going to do this myself on brand new pipes.

I checked into pricing on getting them fixed up locally, but it is pretty expensive ($20/pipe) so I'm going to get the pipes shipped back. V&H says I should get roughly a 1 week turnaround so that's good.
 
Ya, I wouldn't pay for something to get fixed when it was their problem. I think you did the right thing and decided to have V&H pay for the shipping and fix it themselves. At least they can't say you did something to void the warranty.
 
That's good news. Can you post the pictures. Maybe I should have done that first, before filing them down. Not much was needed but when I think about it, it would have taken some of the chrome plating off where corrosion can set in.
 
Bad news.

I shipped the pipes to Vance and Hines and they say they cannot be repaired, and they have to place an order to replace it which will take 4-6 weeks. They offered to do this for me, or to refund Bike Bandit which can then refund me.

I think I'll take their 4-6 week lead-time on order, but I'm going to call Bike Bandit tomorrow to see if they can come up with any other options that don't involve me waiting for a month+, or paying more for shipping/duty. I figure that these new pipes will have the care and attention that they deserved, and I won't have to take a chance on another set of pipes not fitting properly.
 
At this point I'm just writing for therapy.

Bike Bandit says they have another set in their warehouse, and I've decided that I'd rather have them sooner or later - blow the risk on another set of weirdly shaped pipes.

So here's the bureaucratic mess of it, I need V&H to send the defective pipes back to me, so I can send them to Bike Bandit. At least it is all pre-paid shipping labels.
 
just a heads up for what it's worth but V&H pipes have been crap for the last few years...over a decade IMO.
they would rather sell big fat mig welded Harley pipes for several hundred a pair.
 
blowerbike said:
V&H pipes have been crap for the last few years...over a decade IMO
Click to expand...

That may or may not be true, but I did research the issue here and most people said that they were the best of the two options for replacement pipes.

Let's say I was to start over. My current pipes are rusted to the point that they're only good for scrap metal. I want as close to a stock experience (so no straight pipes for me) but I don't want to buy used pipes from eBay/whatever because they'll just be half-way rusted already. What would you recommend?
 
thewozza said:
So here's the bureaucratic mess of it, I need V&H to send the defective pipes back to me, so I can send them to Bike Bandit.
Click to expand...

I managed to slice through the red-tape and now nobody needs to ship pipes anywhere, except to me. Bike Bandit says my next set of pipes is already out for delivery!
 
thewozza said:
That may or may not be true, but I did research the issue here and most people said that they were the best of the two options for replacement pipes.

Let's say I was to start over. My current pipes are rusted to the point that they're only good for scrap metal. I want as close to a stock experience (so no straight pipes for me) but I don't want to buy used pipes from eBay/whatever because they'll just be half-way rusted already. What would you recommend?
Click to expand...

i was a dealer for years and seen the quality go down..i am just stating facts.
the older bike guys have little choices on new pipes.
i myself would have tried to source a nice used older header but again this is me.
hopefully your replacement header will fit correctly and give you years of joy :D
 
blowerbike said:
hopefully your replacement header will fit correctly and give you years of joy :D
Click to expand...

I got the new pipes last week, and it had the same flaws, but this time on cylinder 2 (the first pipes had the worst flaws on 1 and 4). Tired of waiting I decided to just take a big chance and muscle them on. It was probably stupid to do, but I'm an idiot and I do idiot things. I just kept turning the bolts and that flaw (basically it's a tab on the header that goes into the exhaust port) bent, and it finally stopped moving.

So the V&H pipes are on. I took it for a ride and.............it worked! It doesn't *appear* to be leaking exhaust so I think I've got things seated against the exhaust gaskets and it runs like a champ now. No significant back-firing, and no loss of power like I had with the old pipes.

I should actually upload some pictures of the abomination that was installed on this bike when I bought it, somebody had welded their own 4 into 1 system probably in an attempt to repair the original stuff after it was all rotted out. The central collector was still part of the system, and it had a big hole in it probably about the size of a 25c piece - but the hole was facing up to the oil pan so it was impossible to see it until I got the old exhaust system off. It's all going to the scrap yard in the next run.

I was thinking though, maybe these aren't actually flaws after-all. Maybe these little flaws wouldn't affect fitment on the other range of bikes that the V&H 12009 fits, and the 1981 GS850G just has exhaust ports that are that tiny bit small enough for it to matter. Even if that's the case, I would NOT recommend using the V&H 4 into 1 pipes on a 1981 GS850G as they don't fit properly.
 
I have been vacillating between new pipes and trying to find an old pair in decent shape. Your report isn't encouraging on either front. Not 10 minutes before I read this thread I had made up my mind to use an old set of used pipes. I am nervous now that any used gear I pick up may just set me in for a world of trouble hunting down difficult to diagnose leaks. The new stuff doesn't look much better but at least their customer service sounds acceptable after a little convincing on your part. Thanks for sharing.
 
oddcycle said:
at least their customer service sounds acceptable after a little convincing on your part. Thanks for sharing.
Click to expand...

Definitely, everyone involved has been motivated to help solve this problem. From a customer service standpoint, this has been a good experience.
 
thewozza said:
I was thinking though, maybe these aren't actually flaws after-all. Maybe these little flaws wouldn't affect fitment on the other range of bikes that the V&H 12009 fits, and the 1981 GS850G just has exhaust ports that are that tiny bit small enough for it to matter. Even if that's the case, I would NOT recommend using the V&H 4 into 1 pipes on a 1981 GS850G as they don't fit properly.
Click to expand...

If you were to do it over again from the start what would you do?
 
oddcycle said:
If you were to do it over again from the start what would you do?
Click to expand...

As for stock pipes, ater 30+ years I'm just not sure how many non-rusted exhaust systems are still out there. The only ones I've seen look questionable enough that I wouldn't buy them off eBay - but if you had a set that you could actually look at it might be okay if you can verify that there aren't holes.

I heard MAC makes an alternative:
http://shop.macperformance.com/MAC-...FBC47F1CE3B63A195E1A5C6BA53867.m1plqscsfapp02

But since I wrote that bit about not recommending V&H on the GS850 I've softened my position a bit. the devil you know is better than than devil you don't. Knowing V&H's willingness to work with me on the issues was reassuring, and they were adamant that these pipes were supposed to fit so it's possible that it was just a bad run they had manufactured.
 
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