S&S Cycle Power Tune Sport Exhaust System for 2004 and later Harley-Davidson Sportster Models (PN 550-0230 and 550-0231) User Manual
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Kit Contents:
Exhaust System Kit
• Header assembly
• Heat shields
• Header attachment bracket
• Exhaust port gaskets
End cap kit (packaged separately)
• 2 end caps
• 4 mounting screws
• Loctite® 262
Tools Needed:
• 1/2" socket and ratchet with
extensions
• 1/2" wrench
• 5/8" wrench
• 7/8" wrench
• 3/16" Allen wrench
• 3/8" Allen wrench
• T30 Torx driver
• Snap ring pliers
Removal of stock exhaust system:
1. Secure the motorcycle to prevent tipping during installation.
2. Remove the stock heat shields.
3. Unplug the front and rear oxygen sensors on EFI equipped bikes.
4. Remove the exhaust port flange nuts from each head pipe and
set aside, these will be re-used.
5. Remove the carriage bolt that holds the rear head pipe clamp to
the belt cover.
6. Remove the bolts that hold the mufflers to the crossover tube
bracket.
7. Remove the front and rear exhaust pipe assemblies
8. Remove the stock oxygen sensors on EFI equipped bikes, these
will be re-used
9. Remove the drive belt cover.
10. Using a T30 Torx driver, remove the brake actuation rod from the
rear eyelet section.
11. Remove the stock crossover tube bracket. This will not be re-
used.
12. Remove the circlips and flanges from the stock exhaust system
using a snap ring pliers.
13. Inspect circlips for damage or deformation, replace if necessary.
14. Remove the stock exhaust port gaskets.
Installation of S&S Power Tune Sport Exhaust
1. Remove header and heat shields from protective foam packaging.
Place them in a non-abrasive surface. Unpack the end cap kit.
2. Apply a small amount of Loctite to the supplied screws and
install the end caps to the ends of the heat shields (See Picture
1, above.) Keep the remaining Loctite, it will be needed again in
later steps
3. Using a marker, place a mark on the edge of the heat shield
exactly at the middle of each heat shield hold down clip (See
Picture 2, below left.) This is done to easily locate the clips in
the heat shields at the time of assembling the heat shields onto
the head pipe. Slide the heat shields over the header starting at
the tail end of the header.
4. Install each hose clamp by feeding the tail end of the clamp into
the heat shield clips. Take note of clamp screw head direction.
The screw head must be accessible when the exhaust system is
installed on the motorcycle. Do not fully tighten at this time.
5. Install the exhaust flanges and circlips onto the front and rear
head pipe.
6. Install the supplied mounting bracket to the motorcycle
transmission (See Picture 3.) Apply Loctite to the two 3/8" Allen
head bolts that were previously removed. Torque to 32 ft*lbs.
Make sure the brake actuation rod is placed through the bracket.
Do not install eyelet yet.
7. Install the drive belt cover using the original hardware. Torque
the 3/8" Allen head bolts to 32 ft*lbs and the 1/4" Allen head bolts
85-115 in*lbs. The stock rear exhaust pipe clamp, bracket, and
carriage bolt are not needed with the new header.
Picture 1
Picture 2
Picture 3