TOURING MUFFLER KIT
J042622011-01-20
GENERAL
Kit Number
80677-08, 80721-09, 80742-09, 80847-10, 64900091, 64900093
Models
For the most up-to-date model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Proper installation of these kits requires the separate purchase of two muffler clamps, Harley-Davidson Part Number 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.
Kit Contents
See Figure 3 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.
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.
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 proposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer.
INSTALLATION
1Muffler clamp
Figure 1. Front Muffler Clamp
1Bolt, 5/16-18 x 5/8 inch (4)
2Lockwasher (4)
3Rubber mount
Figure 2. Rear Muffler Mount
1.
Remove saddlebags according to service manual instructions.
2.
See Figure 1. Loosen stock muffler clamp (1).
3.
See Figure 2. Remove and retain stock bolts (1), lockwashers (2) and rubber mount (3).
4.
Remove stock muffler. Discard clamp from Step 2.
5.
Place a new muffler clamp on inlet end of muffler and slide muffler onto exhaust pipe.
6.
Secure rear of muffler to sliding bracket with original equipment bolts and lockwashers. Do not tighten bolts.
7.
Position sliding bracket so rubber mount is at center of sliding bracket.
8.
Tighten bolts (1) to 25.7 N·m (19 ft-lbs).
9.
See Figure 1. Position the muffler clamp as shown. The clamp bolt should be vertical.
10.
Tighten clamp bolt to 61–81 N·m (45–60 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)
11.
Wipe muffler clean of all fingerprints. Oil from hands will burn permanently into chrome finish.
12.
Repeat Steps 2 through 11 for opposite side.
13.
Start engine and check for exhaust leaks.
14.
Install saddlebags according to service manual instructions.
SERVICE PARTS
Figure 3. Service Parts:Touring Mufflers
Table 1. Service Parts: Touring Mufflers
Kit
Item
Description (Quantity)
Part Number
80677-08
1
Muffler, Slash Down, chrome, RH
Not Sold Separately
2
Muffler, Slash Down, chrome, LH
Not Sold Separately
80721-09
1
Muffler, Slash Down, chrome, RH
Not Sold Separately
2
Muffler, Slash Down, chrome, LH
Not Sold Separately
80742-09
1
Muffler, Slash Down, black, RH
Not Sold Separately
2
Muffler, Slash Down, black, LH
Not Sold Separately
80847-10
1
Muffler, Slash Down, black, RH
Not Sold Separately
2
Muffler, Slash Down, black, LH
Not Sold Separately
64900091
3
Muffler, Dual NightStick, black, RH
Not Sold Separately
4
Muffler, Dual NightStick, black, LH
Not Sold Separately
64900093
3
Muffler, Dual NightStick, Chrome, RH
Not Sold Separately
4
Muffler, Dual NightStick, Chrome, LH
Not Sold Separately
Items mentioned in text, but not included in kit:
A
Capscrew, hex (4)
2882W
B
Lock washer (4)
7041
C
Muffler clamp (2) (purchase separately)
65296-95A