SCREAMIN' EAGLE SOFTAIL HIGH-FLOW EXHAUST SYSTEM

J068002023-12-21

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
64900828, 64900829	Safety Glasses, Torque Wrench, E-clip Tool, Loctite 243 Blue and Loctite 262 Red, Anti-seize Lubricant

(1) Tightening to torque value or other moderate tools and techniques required

KIT CONTENTS

Figure 1. Kit Contents: Screamin' Eagle Softail High-Flow Exhaust Kit

Table 2. Kit Contents: Screamin' Eagle Softail High-Flow Exhaust Kit

Verify that all contents are present in the kit before installing or removing items from vehicle.
Item	Qty	Description	Part No.	Notes
1	1	Muffler, black	649000976
1	1	Muffler, stainless steel	649001164
2	1	Exhaust mounting bracket	65500103
3	2	Screw	4407
4	1	Saddlebag mounting bracket	90202034
5	2	HO2S adapter	65700021
6	2	Washer	12300039
7	7	Clamp	9954
8	5	Clip, exhaust	65400534
9	1	Shield, exhaust, front, black	65400561
9	1	Shield, exhaust, front, stainless steel	65400563
10	5	Screw	10500103
11	1	Shield, exhaust, mid, black	65400604
11	1	Shield, exhaust, mid, stainless steel	65400606
12	1	Shield, exhaust, rear, black	65400562
12	1	Shield, exhaust, rear, stainless steel	65400564
13	1	Shield, exhaust, collector	65400557
14	3	Screw	10201171
15	3	Washer, flat	10300245
16	6	Washer	10600072
17	1	Nut	10100156
18	1	Pipe, header assembly	65600363
19	1	Clamp, exhaust muffler	65900043
20	4	12-point nut	10100137
21	1	Screw	4092
22	1	Label, EPA	14002815

GENERAL

Models

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

Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets

Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.

Installation Requirements

Proper installation of this kit requires ANTI-SEIZE LUBRICANT (98960-97).

All models require ECM calibration with Screamin' Eagle Pro Street Tuner for proper installation.

This kit requires separate purchase of two Heated Oxygen Sensor (HO2S) gasket (11936) and two exhaust port gaskets (65324-83B) which are available from a Harley-Davidson dealer.

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 the year and model motorcycle is required for this installation and is available from:

A Harley-Davidson dealer.
H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.

PRODUCT INFORMATION

Tampering Prohibition

Federal law prohibits any modifications to this exhaust system which cause the motorcycle to exceed Federal noise standards. Use of a 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 original purchaser for purposes other than resale, and to all subsequent buyers. Direct warranty claims to an authorized Harley-Davidson dealer.

NOTE

To avoid penalties under state and local ordinances, repair or replace this product if motorcycle noise increases significantly through use.

Product Information Label contained in this kit is a requirement of the California Air Resources Board (CARB) emission regulation.

Place label on right side of frame directly beneath VIN sticker. This label is not required outside the state of California.

PREPARE

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

1.	Remove saddlebags. See service manual.
2.	Remove left side cover. See service manual.
3.	Remove main fuse. See service manual.

REMOVE

1.	Remove Original Equipment (OE) exhaust system. See service manual. a. Retain retaining rings, exhaust flanges and mounting hardware.
2.	Remove passenger footpeg assemblies. Retain. See service manual.
3.	Remove HO2S. Retain.
4.	Remove HO2S gasket from sensor. Discard.
5.	Remove OE exhaust muffler bracket. a. Retain screws.

INSTALL

1.	Figure 2 Relocate and install footpeg support (1) to frame. a. Figure 3 Align notch in footpeg support with alignment tab on exhaust bracket. NOTE FLHC and FLHCS do not have alignment tabs for the passenger footpeg supports. Align footpeg supports at a 5–15° rearward angle. b. Apply threadlocker to screw (2).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) c. Install screw. Tighten. Torque: 51.5–63.7 N·m (38–47 ft-lbs)
2.	Install detent spring (6) and detent ball (7) into footpeg (5).
3.	Install detent plate (4) onto footpeg. NOTE Hold detent ball into place while installing detent plate to prevent detent ball from falling out. Detent plate should be oriented with detent holes on bottom. Make sure detent ball is aligned with innermost hole in detent plate when installed. NOTE Install footpeg and detent plate as an assembly.
4.	Figure 3 Install footpeg. a. Install footpeg into footpeg support. b. Install clevis pin (3). NOTE When installing E-clip, use E-clip tool to help prevent damage to painted surfaces. c. Install E-clip (8). Special Tool: E-CLIP TOOL (HD-52369)
5.	See Figure 4 and Figure 5. Install HO2S adapters (5) with new gaskets (6) in head pipe. Tighten. Torque: 40.7–59.7 N·m (30–44 ft-lbs) NOTE If reusing HO2S, apply a thin coat of ANTI-SEIZE LUBRICANT (98960-97) on threads of each oxygen sensor.
6.	Figure 5 Install HO2Ss (1) in HO2S adapters (5). Tighten. Torque: 16–19 N·m (12–14 ft-lbs) NOTE Adapters not used with Wideband O2 sensors.
7.	Figure 6 Remove saddlebag puck (2) and screw from OE saddlebag bracket. NOTE Bracket only used on vehicles equipped with stock or Harley-Davidson Parts and Accessories saddlebags. a. Clean chase threads of saddlebag puck (2). b. Apply threadlocker to new screw (21).LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) c. Figure 6 Install new screw (21) and saddlebag puck (2) onto new bracket (4). d. Tighten screw (21). Torque: 10.8–13.6 N·m (8–10 ft-lbs)
8.	Figure 7 Install muffler bracket screws (1) removed earlier. a. Clean threads of screws (1) and hole in frame. b. Apply threadlocker to screws (1).LOCTITE 262 HIGH STRENGTH THREADLOCKER AND SEALANT (RED) (94759-99) c. Figure 7 Install muffler bracket (2) and saddlebag bracket (4), if applicable, to vehicle with screws (1). Tighten. Torque: 54–68 N·m (40–50 ft-lbs)
9.	Figure 8 Install OE exhaust flange (2) and retaining rings (3).
10.	Figure 9 Loosely install head pipe using 12-point nuts (20).
11.	Figure 10 Install muffler clamp (19) on muffler.
12.	Install muffler onto header pipe by sliding over rear header section.
13.	Figure 11 Loosely install muffler mounting screws (3) to bracket (2).
14.	Figure 12 Install nut (17) to header.
15.	Figure 13 Loosely install exhaust shield (13), screws (14), washers (15) and two washers (16). NOTE Insulating washers and fasteners are secured tight in order to hold hardware stack in place during installation. Thread insulating washers onto screws.
16.	Figure 9 Tighten exhaust manifold 12-point nuts (20). Torque: 11.3–13.6 N·m (100–120 in-lbs)
17.	Figure 14 Install mid header shield (11). a. Loosely install mid header shield (11) onto vehicle head pipe with hose clamp (7) only. NOTE Mid head shields are not used on models equipped with factory equipped or Harley-Davidson parts and accessory mid controls.
18.	See Figure 1 and Figure 14. Loosely install rear header shield (12) with hose clamps (7), clips (8) and screws (10).
19.	See Figure 1 and Figure 14. Loosely install front header shield (9) with hose clamps (7), clips (8) and screws (10).
20.	Header shields: Figure 14 a. With muffler and shield loose on vehicle, align to desired location. b. Tighten header shields hose clamps (7). Tighten. Torque: 2.2–4.5 N·m (19–40 in-lbs) c. Tighten header shields front screws (10). Tighten. Torque: 12.2–14.9 N·m (108–132 in-lbs) NOTE Check all header shield screws for proper torque as part of standard pre-ride inspection. Re-torque to spec as necessary.
21.	Muffler: Figure 14 a. Tighten muffler mounting screws (3). Tighten. Torque: 27–32.5 N·m (20–24 ft-lbs) b. Tighten muffler clamp (19). Tighten. Torque: 51.5–58.3 N·m (38–43 ft-lbs)
22.	Muffler shield: Figure 13 a. Install muffler exhaust shield (13) and screws (14). b. Tighten muffler shield screws (14). Tighten. Torque: 12.2–14.9 N·m (108–132 in-lbs)

Figure 2. Footpeg Relocation

1	Footpeg support
2	Screw
3	Clevis pin
4	Detent plate
5	Footpeg
6	Detent Spring
7	Detent ball
8	E-clip

Figure 3. Passenger Footpeg

5	Adapter, HO2S (2)
6	Gasket, HO2S (2)

Figure 4. HO2S Adapter and Gasket

1	HO2S (2)
5	Adapter, HO2S (2)

Figure 5. HO2S and Adapter

2	OE puck, saddlebag
4	Bracket, saddlebag
21	Screw

Figure 6. Saddlebag Puck

1	OE screw, muffler bracket (2)
2	Muffler bracket
4	Saddlebag bracket
A	With saddlebags
B	Without saddlebags

Figure 7. Muffler Bracket

1	Exhaust
2	OE exhaust flange
3	OE retaining ring

Figure 8. Exhaust Flange

20	12-point nuts (2)

Figure 9. 12-Point Nuts

19	Muffler clamp

Figure 10. Muffler Clamp

1	Muffler
2	Muffler bracket
3	Mounting screw (2)

Figure 11. Muffler Mounting Bracket

Nut

Figure 12. Nut

13	Exhaust shield
14	Screw (3)
15	Washer (3)
16	Washer (6)

Figure 13. Exhaust Shield with Hardware

1	Muffler
3	Mounting screw, muffler bracket (2)
7	Muffler clamp (7)
9	Shield, exhaust, front
10	Screw (5)
11	Shield, header, mid (not used on mid-control models)
12	Shield, exhaust, rear
13	Exhaust shield
14	Screw, exhaust shield (3)
19	Clamp

Figure 14. Shields

COMPLETE

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)

1.	Install main fuse. See service manual.
2.	Install left side cover. See service manual.
3.	Install saddlebags. See service manual.