S&S Cycle Power Tune Duals For Touring Models 1995-2008 (PN 550-0003 & 550-0142) - Manual (Page 2)

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ATTENTION INSTALLER (if other than owner):
Please forward this instruction sheet to the purchaser of this product. These instructions also contain valuable information necessary to the end user.
INTRODUCTION
These instructions describe the procedure for properly installing S&S® Power Tune Duals. Review instructions carefully before beginning, as they
contain important information. Please retain for future reference.
All Models:
NOTES:
•
This system may not be compatible with swing arm pivot suspension stabilizers.
•
Right side floorboard must be mounted in the lowest position.
•
On pre- 1999 models the brake pedal may need to be modified to gain additional clearance to the heat shield.
Ground and cornering clearance may be reduced. Clearance will be reduced when bikes are fitted with shorter shocks.
TOOLS REQUIRED
1 – ¼" drive ratchet
1 – 7/16" box wrench 1 – ¼" nut driver
1 – ¼" drive ½" socket 1 – ½" box wrench 1 – 15mm box wrench
1 – 3/16" Allen wrench 1 – 9/16" box wrench 1 – 3/8" Allen wrench
1 – ¼" drive 6" extension 1 – 5/16" Allen wrench
Supplies: New muffler clamps and 243 Loctite®.
PROCEDURE
1- Remove right front floorboard and floorboard brackets.
2- Remove saddlebags.
3- Remove mufflers, save clamps (Harley-Davidson® states clamps are not reusable). See step 19.
4- Disconnect the O2 sensors (2007-up). Remove heat shields and exhaust headers. Save the 5/16-24 hex flange port nuts.
5- Remove and save retaining rings and exhaust flanges from old exhaust headers.
6- Remove the rear exhaust bracket mounted to transmission, this bracket is not needed. Remove transmission end cover to access fasteners
(1999-'06). Replace screws.
7- Remove the left side exhaust/starter bracket. Replace screws.
8- Remove and discard four of the ¼" socket heads closest to the rear of the oil pan (leave center rear screw intact). See the photo.
9- Remove and discard exhaust port gaskets. Install new conical gaskets.
New conical port gaskets (S&S 106-5029) must be used to avoid leaks.
10- Install flanges and retaining rings on new exhaust headers. Oxygen sensors and/or supplied plugs/gaskets may be installed at this time. Use
anti-seize on threads.
11- Install new header system using saved 5/16-24 hex flange nuts. Seat front pipe first then rear. A firm pull rearward on the rear header, while
keeping the front header seated, may be necessary to clear the rear head casting. Be careful not to damage gaskets. Do not fully tighten
nuts yet.
12- Install the supplied Torca/AccuSeal pipe clamp on the expanded end of the crossover pipe weldment with the open end down and the nut
facing out (cannot be installed later).
13- Position the crossover weldment under the oil pan and slide its expanded end onto the end of the front header pipe.
14- Align the slots in the crossover pipe mounting brackets with the oil pan mounting holes. Install the four ¼-20 x 3.50" hex cap screws, ¼" flat
washers and the two crossover spacer weldments. Use 243 Loctite on the threads. Torque the fasteners to 90-108 in-lbs.
15- Torque the port flange nuts evenly. Do not tighten the Torca clamp until the heat shields are in place.
To ensure there are no leaks and the system is properly aligned the front and rear port nuts must be evenly torqued.
16- Clean header pipes and crossover (see step 22).
17- Insert worm gear clamps into slots on the back side of the heat shields. All clamp screws except the upper two on the rear shield should be
positioned so the screw heads can be accessed from the front or bottom of the headers. Tip: Insert clamps halfway into the slots and bend the
ends outward to ease installation over header pipes.
CAUTION
WARNING
CAUTION