SPORTSTER SHORTY DUAL SLIP-FIT MUFFLERS - Harley
Contents
1. any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard Use of the motorcycle with such a modified exhaust system is also prohibited Noise Emission Warranty Harley Davidson warrants that these mufflers at the time of sale meets all applicable United States E P A Federal noise J01237 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled and Emissions standards This warranty extends to the first person who buys these mufflers for proposes other than resale and to all subsequent buyers Warranty claims should be dir ected to an authorized Harley Davidson Dealer NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use Otherwise the owner may become subject to penalties under state and local ordinances INSTALLATION WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 1 Remove the main fuse 2 Loosen stock muffler clamps 3 The front muffler is held to a stud on the sprocket cover with a locknut To access the locknut remove the master cylinder mounting bolts and lift the brake pedal upward Remove the locknut and remove front muffler 4 Remove locknut and bolt that attaches rear muffler to muffler support and remove rear muffler 5 Loosen head pipe nuts at c2. cMOTOR HARLEY DAVIDSON WY J01237 INSTRUCTIONS REV 2009 11 05 SPORTSTER SHORTY DUAL SLIP FIT MUFFLERS GENERAL Kit Numbers 80102 97 80110 97 80306 99 80310 99 80363 99 Models These kits are designed to fit 1998 2003 XL except 883R 1992 2003 883 Hugger 1996 2003 XL1200C and 1992 2003 XL equipped with Profile Low Rear Suspension 54571 94A Additional Parts Required Proper installation of this kit requires the separate purchase of two muffler clamps 65296 95A Due to the increased diameter of these mufflers as compared with original equipment some realignment of headpipes is usually required It is recommended that the exhaust port gaskets 65324 83A be replaced to avoid the tendency of the headpipes to return to the original position when tightened AWARNING The rider s safety depends 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 00333a NOTE This instruction sheet references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson dealer Kit Contents See Figure 1 and Table 1 PRODUCT INFORMATION Tampering Prohibition Federal law prohibits
3. ylinder head exhaust studs until headpipes move freely 6 Install new mufflers and new muffler clamps and stock mounting hardware a Tighten head pipe nuts to 6 8 ft lbs 8 11 Nm b Tighten locknut at sprocket cover stud to 20 40 ft lbs 27 54 Nm c Tighten muffler clamps to 35 40 ft lbs 47 54 Nm d Tighten locknut for rear muffler support to 10 15 ft lbs 14 20 Nm e Tighten master cylinder mounting bolts to 155 190 in lbs 17 21 Nm 7 Install the main fuse 1 of2 Please dispose of materials responsibly SERVICE PARTS is00115 Figure 1 Dyna Slip on Mufflers Table 1 Service Parts Table Kit Item Description Quantity Part Number 80102 97 1 Slash cut e Slash cut rear 80150 97 e Slash cut front 80149 97 80110 97 1 Blunt cut e Blunt cut rear 80152 97 e Blunt cut front 80151 97 80306 99 1 Slash cut black e Slash cut rear black 80305 99 e Slash cut front black 80304 99 80310 99 1 Slash down black e Slash down rear black 80309 99 e Slash down front black 80307 99 80363 99 1 Slash down black e Slash down rear black 80361 99 e Slash down front black 80362 99 Items mentioned in text but not included in kit A Clamp muffler 2 65296 95A J01237 2 of 2
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