S&S Cycle Power Tune Duals for Touring Models 2009–Up (PN 550-0004 and 550-0143) - 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.
•
2010 Street Glide®/Road Glide® Custom models with OEM 2-1 exhaust system will require the purchase of the following Harley-Davidson® components:
65296-95A (hanger bracket), 65724-85 (rubber isolator), 65723-85 (exhaust clamp)
Ground and cornering clearance may be reduced. Clearance will be reduced when bikes are fitted with shorter shocks.
TOOLS REQUIRED
¼ " drive ratchet
5/16" Allen wrench 6mm Allen wrench
¼" drive 6" extension 7/16" box wrench 10mm Allen wrench
¼" drive ½" socket ½" box wrench 14mm box wrench
3/16" Allen wrench 9/16" box wrench 15mm box wrench
¼" Allen wrench ¼" nut driver or flat screwdriver 22mm box wrench
Supplies: New muffler clamps, 272 red Loctite® or equivalent, and anti-seize.
PROCEDURE
1- Remove right front floorboard.
2- Remove saddlebags.
3- Remove mufflers, save clamps (Harley-Davidson® states clamps are not reusable). Tip: Use anti seize on threads of used muffler clamps. If they
clamp down securely they don't need to be replaced.
4- Disconnect the O
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sensors. Remove heat shields and exhaust headers. Save the 5/16-24 hex flange port nuts.
5- Remove and save O
2
sensors, retaining rings and exhaust flanges from old exhaust headers.
6- Remove the crossover pipe clamp and bracket from the transmission, these parts are not needed. Replace the socket head screws.
7- Remove the four ¼" socket head bolts closest to the rear of the oil pan (leave center rear bolt intact). These bolts are no longer needed. See the
photo.
8- Remove and discard exhaust port gaskets. Install new conical gaskets.
New conical port gaskets (H-D 65324-83B) (S&S 106-5029) must be used to avoid leaks.
9- Install flanges and retaining rings on new exhaust headers. Oxygen sensors and supplied plugs/gaskets may be installed at this time. Use the
supplied plugs/gaskets to cap the remaining ports. Use anti-seize on threads.
10- 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.
11- Install the crossover spacer weldment (counterbored side down) to the oil pan using the four ¼-20 x 2.25" socket head cap screws and ¼" lock
washers. Important: Apply 272 Loctite to the threads and torque the fasteners to 90-108 in-lbs.
12- Install the silicone grommets and steel bushings in the crossover pipe weldment L-bracket. Install the supplied Toraca/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. Align the bushings in the
crossover weldment L-bracket with the threaded holes in the oil pan bracket weldment. Apply 272 Loctite on the threads and loosely install
the two 5/16-24 x 0.75" hex cap screws and large diameter 5/16" flat washer.
14- Install mufflers and clamps. Tip: Use anti seize on threads of the muffler clamp. Muffler rear brackets should align side to side and up and down
with the saddle bag support rear mounting brackets without stress. Torque the crossover mounting screws to 20 ft-lbs. Next, torque the port
flange nuts evenly. Do not tighten the muffler or crossover/header clamps 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.
WARNING
CAUTION
CAUTION