SOFTAIL® SHORTY-DUAL MUFFLER SLIP-ON KITS

J038992006-09-18

GENERAL

Kit Numbers

80494-07, 80495-07

Models

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

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.

Additional Parts Required

Proper installation of these kits requires the separate purchase of two muffler clamps, Harley-Davidson Part Number 65283-94.

Kit Contents

See Figure 1 and Table 1.

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, meet all applicable United States E.P.A. Federal noise and Emissions standards. This warranty extends to the first person who buys these mufflers for purposes 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.
	WARNING Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311b)
2.	Remove mufflers according to applicable Service Manual instructions. Staggered dual mufflers will come off the vehicle attached to the interconnect tube.
3.	Remove mufflers from interconnect tube and discard gaskets and mufflers.
4.	See Figure 1. Install mufflers to interconnect tube using new gaskets (1) and existing screws. Slip muffler clamps (A) on mufflers and install assembly back on vehicle. Tighten screws to 10.8–13.6 N·m (96–120 in-lbs). Tighten muffler clamps to 61–81.3 N·m (45–60 ft-lbs). Attach the interconnect tube to the frame using the existing flange lock nuts and washers. Tighten to 40.7–44.7 N·m (30–33 ft-lbs).
	NOTICE Wipe all fingerprints off of exhaust system components after installation and before starting engine. Oil from hands can leave permanent marks on exhaust system finish. (00346a)
5.	Wipe muffler clean of all finger prints. Oil from hands will burn permanently into chrome finish.
6.	Connect the negative (-) battery cable.
7.	Start motorcycle and check for exhaust leaks.

SERVICE PARTS

Figure 1. Service Parts: Slip-On Muffler Kit

Table 1. Service Parts: Slip-On Muffler Kit

Kit	Item	Description (Quantity)	Part Number
80494-07	1	Exhaust interconnect gasket (2)	65927-00
	2	Muffler assembly, Baloney cut, rear	80524-07
	3	Muffler assembly, Baloney cut, front	80525-07
80495-07	1	Exhaust interconnect gasket (2)	65927-00
	4	Muffler assembly, Slash down, rear (not shown)	80510-07
	5	Muffler assembly, Slash down, front (not shown)	80511-07
Items mentioned in text but not included in kit (Must be purchased separately).
	A	Muffler clamp (2)	65283-94