1. | Remove main fuse. See the owners manual. | |
2. | Remove saddlebags. See the owners manual. | |
3. | Remove the original equipment (OE) exhaust system. Retain exhaust flanges and mounting hardware for later installation. See the service manual. | |
4. | Remove heated oxygen sensors (HO2S) and retain for installation. | |
5. | Remove the used HO2S gasket from sensor and install a new gasket to the HO2S (gasket sold separately). | |
6. | See Figure 1. Install HO2S adapter with supplied gaskets (11) in new head pipe. Torque: 40.7–59.7 N·m (30–44 ft-lbs) | |
7. | Install HO2S in new head pipe adapters (17). Torque: 16–19 N·m (12–14 ft-lbs) | |
8. | NOTE Do not tighten hardware until directed to do so. | |
9. | Loosely install new head pipe (1). | |
10. | Install the cross over pipe gasket (11) onto the head pipe then loosely install the cross over pipe (16) and clamp (8). | |
11. | Loosely install the cross under pipe hanger (10) and bolt. | |
12. | Install the supplied clamps (9) into the mufflers and slide the mufflers (2 and 3) into the pipes. | |
13. | Install the rear muffler support and screws. See the service manual. Torque: 19–24.4 N·m (14–18 ft-lbs) | |
14. | Tighten exhaust manifold nuts. See the service manual. Torque: 11.3–13.6 N·m (8–10 ft-lbs) | |
15. | Tighten the transmission exhaust bracket nut. See the service manual. Torque: 20.3–27.1 N·m (15–20 ft-lbs) | |
16. | Tighten the cross over pipe bracket bolt. See the service manual. Torque: 19–24.4 N·m (14–18 ft-lbs) | |
17. | Tighten the cross over pipe clamp (8). Torque: 51.5–58.3 N·m (38–43 ft-lbs) | |
18. | Install front (4) and rear (5) header pipe shields. Torque: 2.2–4.5 N·m (19–40 in-lbs) | |
19. | Position and align collector shield (6) with front and rear header pipe shields. Torque: 2.2–4.5 N·m (19–40 in-lbs) | |
20. | Install the cross over pipe shield (7). Torque: 2.2–4.5 N·m (19–40 in-lbs) | |
21. | Tighten the muffler clamps (9). Torque: 51.5–58.3 N·m (38–43 ft-lbs) |
Item | Description | QTY | Part Number | Item | Description | QTY | Part Number |
---|---|---|---|---|---|---|---|
1 | Header assy., performance | 1 | Not sold separately | 8 | Clamp, muffler | 1 | 65900007 |
2 | Muffler, RH - 4.5 OD | 1 | 64900557 - Chrome | 9 | Clamp, muffler | 2 | 65900010 |
64900616 - Black | 10 | Clamp, hinged | 1 | 65900039 | |||
3 | Muffler, LH - 4.5 OD | 1 | 64900558 - Chrome | 11 | Gasket, muffler - headed | 1 | 65900040 |
64900619 - Black | 12 | Clamp, worm - #28 | 4 | 9954 | |||
4 | Shield, front | 1 | 65400358 - Chrome | 13 | Clamp, worm - #24 | 4 | 9955 |
65400359 - Black | 14 | Washer | 2 | 12300039 | |||
5 | Shield, rear | 1 | 65400360 - Chrome | 15 | Label, EPA | 1 | Not sold separately |
65400361 - Black | 16 | Pipe, cross over | 1 | Not sold separately | |||
6 | Shield, collector | 1 | 65400362 - Chrome | 17 | Adaptor, HO2S | 2 | 65700021 |
65400363 - Black | 18 | Clamp, worm - #28 | 1 | 65900042 | |||
7 | Shield, LH | 1 | 65400367 - Chrome | ||||
65400366 - Black |