Evolution Softail Exhaust System Removal

Mike is getting ready to tear down the top end of our 1988 Heritage Softail. Before doing so, there are a handful of components that will need to be removed. The Evolution Softail exhaust system is the main bulky item. The left & right side fuel tanks have already been removed. The tank halves have been set aside and placed in a safe area where they are covered with a clean towel.

Softail Evolution fuel tanks have rubber grommets at the mounting points. There are three for each tank half. These rubber grommets will deteriorate over time. If the grommets are dry rotted or cracked, it is important that they are replaced. Fuel tank grommets are cheap. When removing the fuel tanks, it is also important to verify or determine if there is any missing or incorrect mounting hardware. It is very common to have missing or incorrect mounting hardware on older motorcycles. Especially if a number of people have already worked on the motorcycle.

Evolution Tank Removal Video

Next, Mike removes the top motor mount. He unplugs the vacuum advance switch (VOES or VOS) and the horn which are mounted onto the top motor mount. Again, Mike stresses the importance of inspecting the motor mount for cracking and for correct mounting hardware. Often, if a top motor mount is cracked, it will be because it was mounted incorrectly or mounted with incorrect hardware.

When an Evolution Softail exhaust system has been in place for many years, it is common to have rusted and seized hardware. If the Softail exhaust system hardware looks excessively rusted, it is good practice to begin soaking rusted hardware with a premium rust penetrant a day or two prior to attempting removal. PB Blaster is one of our favorites.

At the front & rear heads; the Softail exhaust stud nuts can often be difficult to remove. It is very important to practice patience if one or more of these nuts are frozen. Besides using a rust penetrant, it is important to work the frozen nut back and forth, repeatedly. Using heat is also very helpful. Breaking an exhaust stud must be avoided. Usually a broken exhaust stud means that the head will need to be pulled in order to make a correct repair.

Next up, Mike will be removing the air cleaner assembly, the carburetor, and the intake manifold.