1. | Remove both saddlebags per the service manual. | |
2. | See Figure 1. Loosen the front muffler clamp (A or B). | |
3. | See Figure 2. Remove and retain the rear muffler mount bolts (C) and lockwashers (D). | |
4. | Remove the currently installed muffler (1 or 2). Discard the front muffler clamp (A or B) loosened earlier. | |
5. | If necessary, install muffler end caps per the instructions in that kit. | |
6. | Place the correct new muffler clamp (A or B) on the inlet end of the muffler (1 or 2). Slide the muffler onto the exhaust pipe (E or F). | |
7. | Secure the rear of the muffler (1 or 2) to the sliding bracket (G) with original equipment bolts (C) and lockwashers (D). Leave fasteners loose. | |
8. | Position the sliding bracket so the rubber mount (H) is at the center of the sliding bracket. | |
9. | Tighten bolts (C). Torque: 18.9–24.2 N·m (14–18 ft-lbs) muffler bolt | |
10. | See Figure 1. Position the muffler clamp (A or B) as shown, with the clamp bolt in a vertical position. | |
11. | Tighten the clamp bolt. Torque: 51.6–58.5 N·m (38–43 ft-lbs) clamp bolt | |
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) | ||
12. | Wipe the muffler clean of all fingerprints. Oil from hands burns permanently into the finish. | |
13. | Repeat Steps 2 through 12 for the opposite side. | |
14. | Start engine. Check for exhaust leaks. | |
15. | Install saddlebags per the service manual. |
1 | Muffler, right side |
2 | Muffler, left side |
3 | End cap (2) |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Muffler, right side, Domestic (black) | 64900856 |
Muffler, right side, Domestic (chrome) | 64900861 | |
Muffler, right side, HDI (black) | Not sold separately | |
Muffler, right side, HDI (chrome) | Not sold separately | |
Muffler, right side, HDI (black) | 64901204 | |
Muffler, right side, HDI (chrome) | 64901207 | |
2 | Muffler, left side, Domestic (black) | 64900859 |
Muffler, left side, Domestic (chrome) | 64900858 | |
Muffler, left side, HDI (black) | Not sold separately | |
Muffler, left side, HDI (chrome) | Not sold separately | |
Muffler, left side, HDI (black) | 64901203 | |
Muffler, left side, HDI (chrome) | 64901206 | |
3 | End cap kit, HDI (black) | 65100076A |
End cap kit, HDI (chrome) | 65100078 | |
Items mentioned in text, but not included in kit. | ||
A | Clamp, right side muffler (Part No. 65900015) | |
B | Clamp, left side muffler (Part No. 65900012) | |
C | Cap screw, hex head (4) (Part No. 3929) | |
D | Lockwasher (4) (Part No. 7041) | |
E | Exhaust pipe, right side | |
F | Exhaust pipe, left side | |
G | Sliding bracket (2) | |
H | Rubber mount (2) |