PART NUMBER | TOOL NAME |
PFSX916 | SNAP-ON WRENCH |
To facilitate removing exhaust pipe header nuts, use SNAP-ON WRENCH (Part No. PFSX916).
![](https://motoinstruction.ru/img/harley/12/118100.jpg)
Figure 4-65. Exhaust system, all XL models: 1. Muffler, front; 2. Muffler, rear; 3. Exhaust pipe, front; 4. Exhaust pipe, rear; 5. Muffler interconnect bracket; 6. Torca muffler clamp assembly (2); 7. Exhaust port gasket (2); 8. Exhaust gasket retaining ring (2); 9. Exhaust pipe flange (2); 10. Nut (4); 11. Heat shield, front exhaust pipe; 12. Heat shield, rear exhaust pipe; 13. Worm drive clamp (5); 14. Muffler heat shield (2) (HDI, England, Japan, Brazil) (2); 15. Worm drive clamp (4); 16. Flanged bolt (4); 17. Screw (3); 18. Washer (3); 19. Muffler interconnect gasket (2); 20. Exhaust pipe clamp; 21. Exhaust pipe clamp bracket; 22. Acorn nut; 23. Screw; 24. Engine sprocket cover; 25. Screw; 26. Washer; 27. Front O2 sensor assembly; 28. Rear O2 sensor assembly; 29. Seal ring (2); 30. O2 sensor connectors (2): [137], [138]; 31. Heat shield, rear exhaust pipe (mid-control vehicles only)
Removal
Mufflers and exhaust pipes
Note. See Figure 4-66. Vehicles with mid controls are equipped with an extra heat shield (2) on the rear exhaust pipe.
![](https://motoinstruction.ru/img/harley/12/118101.jpg)
Figure 4-66. Rear exhaust pipe heat shields: vehicles with mid controls: 1. Top heat shield; 2. Bottom heat shield; 3. Upper worm drive clamp; 4. Lower worm drive clamp
1. See Figure 4-65. Remove heat shields:
- a. Models with Mid Controls: Remove worm drive clamps (13) from heat shield (12) completely. Remove bottom heat shield.
- b. All Models: Open worm drive clamps (13) and remove exhaust pipe heat shields (11, 12).
- c. HDI, England, Asia Pacific, India, Japan, Brazil Models: Open worm drive clamps (15) and remove muffler heat shields (14).
2. Unplug O2 sensor connectors (30). Front connector [138] is mounted on left front frame downtube. Rear connector [137] is attached to the ECM caddy on the left.
3. Remove nuts (10) from front and rear cylinder head exhaust studs.
4. Remove flanged bolts (16) securing front and rear mufflers (1, 2) to muffler interconnect bracket (5).
5. Loosen Torca muffler clamp assemblies (6) on front and rear mufflers. Remove mufflers. Discard muffler interconnect gaskets (19).
6. Remove and discard Torca clamps.
Note. New Torca muffler clamps have eliminated the need for silicone or graphite tape during assembly. Always use new clamps during installation to maintain sealing integrity and prevent leakage.
7. Remove nut (22) and screw (23) from exhaust pipe clamp (20). Separate exhaust pipe clamp from clamp bracket (21).
8. Remove front and rear exhaust pipes (3, 4). Slide exhaust pipe clamp off rear exhaust pipe.
9. Remove exhaust port gasket (7), retaining ring (8) and exhaust pipe flange (9) from each exhaust pipe. Discard gasket.
10. Remove O2 sensor assemblies (27, 28) from front and rear exhaust pipes. Discard seal rings (29). See 4.12 OXYGEN (O2) SENSOR.
Muffler interconnect bracket
1. See Figure 4-67. Remove screw (6), washer (5) and exhaust pipe clamp bracket (4). Remove two screws (2, 3). Remove sprocket cover (1).
![](https://motoinstruction.ru/img/harley/12/118102.jpg)
Figure 4-67. Sprocket cover: 1. Sprocket cover; 2. Screw; 3. Screw; 4. Exhaust pipe clamp bracket; 5. Washer; 6. Screw
2. See Figure 4-68. Remove rear brake rod (1) at bell crank (2).
![](https://motoinstruction.ru/img/harley/12/118103.jpg)
Figure 4-68. Rear brake linkage: 1. Rear brake rod; 2. Bell crank; 3. Rear brake master cylinder assembly; 4. Rear brake pedal; 5. Frame
3. See Figure 4-65. Remove three screws (17) and washers (18) securing muffler interconnect bracket (5) to engine crankcase. Remove muffler interconnect bracket.
Installation
PART NUMBER | TOOL NAME |
PFSX916 | SNAP-ON SWIVEL BALL SOCKET EXTENSION |
FASTENER | TORQUE VALUE | |
Muffler interconnect bracket mounting screw: XL Models | 30-33 ft·lbs | 40.7-44.7 Nm |
Brake rod to bell crank screw | 120-180 in·lbs | 13.6-20.4 Nm |
Exhaust pipe clamp bracket screw: XL Models | 30-33 ft·lbs | 40.7-44.8 Nm |
Sprocket cover, forward and lower screws | 80-120 in·lbs | 9.0-13.6 Nm |
O2 sensor | 29-44 ft·lbs | 39.3-59.7 Nm |
Mufflerto interconnect bracket screw: XL Models | 15-19 ft·lbs | 20.4-25.8 Nm |
Cylinder head exhaust port nut | 96-120 in·lbs | 10.9-13.6 Nm |
Muffler torca clamp nut | 38-43 ft·lbs | 51.6-58.4 Nm |
Exhaust pipe clamp nut: XL Models | 20-30 ft·lbs | 27.1-40.7 Nm |
Exhaust heat shield clamps | 20-40 in·lbs | 2.3-4.5 Nm |
Muffler interconnect bracket
1. See Figure 4-65. Install muffler interconnect bracket (5) to engine case with three screws (17) and washers (18). Tighten to 30-33 ft·lbs (40.7-44.7 Nm).
2. See Figure 4-68. Apply two drops of LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (blue) to rear brake rod ball stud screw. Attach rear brake rod (1) to bell crank (2). Tighten screw to 120-180 in·lbs (13.6-20.4 Nm).
3. See Figure 4-67. Install sprocket cover (1). Install but do not tighten the screws (2, 3). Note that long screw goes in top hole, short screw in bottom hole.
4. Install exhaust pipe clamp bracket (4), washer (5) and screw (6). Tighten to 30-33 ft·lbs (40.7-44.8 Nm). Now tighten screws (2, 3) to 80-120 in·lbs (9.0-13.6 Nm).
Exhaust pipes and mufflers
Notes:
- To facilitate installing exhaust pipe header nuts, use SNAP-ON SWIVEL BALL SOCKET EXTENSION (Part No. PFSX916).
- If reusing the O2 sensors, apply a thin coat of ANTI-SEIZE LUBRICANT to the threads prior to installation. Do not use any other grease or sealant product on sensor threads.
- The electrical connector must also be clean and free of dielectric grease.
1. See Figure 4-65. If the front and rear O2 sensor assemblies (27, 28) are being reused, install new seal rings (29) onto each sensor. Apply a thin coat of ANTI-SEIZE LUBRICANT to the sensor threads.
2. Install sensor assemblies into front and rear exhaust pipes. Tighten to 29-44 ft·lbs (39.3-59.7 Nm). See 4.12 OXYGEN (O2) SENSOR.
3. Place exhaust pipe flange (9), exhaust gasket retaining ring (8) and new exhaust port gasket (7) over front end of each exhaust pipe (3, 4). Position flange so that inside counterbore faces cylinder head exhaust port.
4. Position front ends of front and rear exhaust pipes into front and rear cylinder heads, respectively. Position holes in flanges over mounting studs and loosely install nuts (10). Do not tighten nuts at this time.
5. Install exhaust pipe clamp (20) on rear exhaust pipe (4) with square hole facing down. Assemble exhaust pipe clamp to exhaust pipe clamp bracket (21) with screw (23) and acorn nut (22). Verify that the bracket fits between ends of clamp. Do not tighten at this time.
6. Install new muffler interconnect gaskets (19) in interconnect mating holes in mufflers (1, 2).
7. Place new Torca clamp assemblies (6) over slotted end of each muffler. Install each muffler onto the end of its respective exhaust pipe.
8. Rotate both mufflers until their mounting bosses line up with holes in muffler interconnect bracket. Carefully mate each muffler with exhaust port in interconnect bracket. Loosely install flanged bolts (16). Do not tighten at this time.
9. Tighten exhaust system fasteners in the following sequence:
- a. Tighten four flanged bolts securing mufflers to interconnect bracket to 15-19 ft·lbs (20.4-25.8 Nm).
- b. Tighten four nuts at cylinder head exhaust studs to 96-120 in·lbs (10.9-13.6 Nm).
- c. Tighten two Torca clamps to 38-43 ft·lbs (51.6-58.4 Nm).
- d. Tighten rear exhaust pipe clamp nut (22) to 20-30 ft·lbs (27.1-40.7 Nm).
10. Plug in O2 sensor connectors (30). Front connector [138] is mounted on left front frame downtube. Rear connector [137] is attached to the left side of the ECM caddy. See 4.12 OXYGEN (O2) SENSOR.
11. Install heat shields:
- a. Open worm drive clamps (13) and install heat shields (11, 12) on exhaust pipes. Position each clamp so that screw is on the outboard side in the most accessible position.
- b. Models with Mid Controls: See Figure 4-66. Tighten lower worm drive clamp (4) a few turns. Slide lower portion of bottom heat shield (2) into lower worm drive clamp. Engage upper portion of bottom heat shield into upper worm drive clamp (3).
- c. All Models: Tighten all exhaust pipe heat shield clamps to 20-40 in·lbs (2.3-4.5 Nm).
- d. HDI, England, Asia Pacific, India, Japan and Brazil Models: Open worm drive clamps (15). Install the muffler heat shields (14). Position each clamp so that screw is on the outboard side in the most accessible position. Tighten clamps securely.