Sportster Accessory Slip-On Muffler Kits

J034412009-11-05

GENERAL

Kit Numbers

80416-06 and 80417-06

Models

For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).

Kit Contents

See Figure 1 and Table 1.

Additional Parts Required

Proper installation of this kit requires the separate purchase of two muffler clamps (65296-95A).

WARNING

Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)

NOTE

This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer.

PRODUCT INFORMATION

Tampering Prohibition

Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited.

Noise Emission Warranty

Harley-Davidson warrants that these mufflers, at the time of sale, meets all applicable United States E.P.A. Federal noise and Emissions standards. This warranty extends to the first person who buys these mufflers for proposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer.

NOTE

This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

INSTALLATION

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

WARNING

Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a)

1.	Disconnect negative (-) battery cable.
2.	Remove mufflers using appropriate service manual instructions.
3.	Discard gaskets and mufflers.
4.	Install new gaskets on mufflers.
5.	Slip muffler clamps on mufflers.
6.	Loosely attach mufflers to the interconnect tube using existing screws and washers.
7.	Position the ends of the front and rear exhaust pipes into front and rear cylinder heads and align exhaust system while tightening all nuts and bolts; beginning at the cylinder head exhaust ports and work back toward the mufflers. a. Finger tighten the upper nuts to the mounting studs. b. Tighten the lower nut to 1–2.1 N·m (9–18 in-lbs). c. Tighten the upper nut to 6.8–9 N·m (60–80 in-lbs). d. Tighten the lower nut to 6.8–9 N·m (60–80 in-lbs).
8.	Tighten the acorn nut on the rear exhaust pipe support clamp to 20.3–25.8 N·m (15–19 ft-lbs).
9.	Tighten muffler clamps to 61–81.3 N·m (45–60 ft-lbs).
10.	Tighten screws and washers to 20.3–25.8 N·m (15–19 ft-lbs).
11.	Connect negative (-) battery cable.

SERVICE PARTS

Figure 1. Service Parts: Sportster Accessory Slip-on Muffler Kits

Table 1. Service Parts: Sportster Accessory Slip-on Muffler Kits

Kit	Item	Description (Quantity)	Part Number
Kit 80416-06	1	Gasket (2)	65927-00
		Shorty-Dual slash down muffler assembly (not shown)
	2	Rear	80391-04
	3	Front	80467-06
Kit 80417-06	1	Gasket (2)	65927-00
		Shorty-Dual tapered baloney cut muffler assembly
	2	Rear	80411-04
	3	Front	80469-06
Items mentioned in text, but not included in kit:
	A	Clamp, muffler (2)	65296-95A