SPORTSTER ACCESSORY SLIP-ON MUFFLER KITS

J057132015-10-28

GENERAL

Kit Numbers

64900208A, 64900209A, 64900322, 64900325

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).

Installation Requirements

Proper installation of these kits requires the separate purchase of two muffler clamps (Part No. 65283-94A).

Kits 64900208A and 64900209A do not contain muffler end caps. End caps can be purchased separately from a Harley-Davidson dealer. 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 refers to service manual information. A service manual for your year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.

Kit Contents

See Figure 2 and Table 1.

PRODUCT INFORMATION

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.

The Product Information Labels contained in kits 64900208A and 64900209A are a requirement of the California Air Resource Board (CARB) emission regulation.

Place this label on the right side of the frame directly beneath the VIN sticker.

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.

NOTE

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

INSTALLATION

WARNING

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

1.	Remove main fuse.
2.	Allow the exhaust to cool before starting disassembly.
3.	Remove the original muffler shields. Save for installation.
4.	Remove the original equipment mufflers. See the service manual.
5.	Install the original muffler clamps onto the new mufflers.
6.	Align exhaust system while tightening all nuts and bolts. Begin 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).
7.	Tighten the acorn nut on the rear exhaust pipe support clamp to 20.3–25.8 N·m (15–19 ft-lbs).
8.	Tighten muffler clamps to 61–81.3 N·m (45–60 ft-lbs).
9.	Tighten screws and washers to 20.3–25.8 N·m (15–19 ft-lbs).
10.	Install worm drive clamps with muffler shields.

Figure 1. Muffler Shield Clamp Screw Orientation

NOTE

See Figure 1. Install the front muffler shield rear clamp screw as shown. If installed below the muffler, clamp screw can contact ground at maximum lean angle.

11.	Align other clamp screws for access and clearance.
12.	Tighten to 2.4–4.5 N·m (20–40 in-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)
13.	Wipe exhaust system clean.
14.	Install main fuse.

SERVICE PARTS

Figure 2. 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 64900208A	1	Shorty-Dual muffler, chrome front and rear	Not Sold Separately
Kit 64900209A	1	Shorty-Dual muffler, black front and rear	Not Sold Separately
Kit 64900322	1	Shorty-Dual muffler, black front and rear w/ Black muffler shield kit	Not Sold Separately
	2	Black muffler shield kit	65400078
	3	Clamp	Not Sold Separately
Kit 64900325	1	Shorty-Dual muffler, chrome front and rear w/ Chrome muffler shield kit	Not Sold Separately
	2	Chrome muffler shield kit	64806-07A
	3	Clamp	Not Sold Separately