S&S Cycle Power Tune Sport Exhaust System for 2004 and later Harley-Davidson Sportster Models (PN 550-0230 and 550-0231) - Manual (Page 3)

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8. Apply a small amount of Loctite to the brake actuation rod eyelet
thread and re-install. Torque 120-180 in*lbs. It may be necessary
to remove the retaining ring and brake lever pin from the bell
crank on the rear master cylinder to gain access to the eyelet with
the T30 Torx bit. (See Picture 4 above).
9. Install the supplied exhaust port gaskets taking care not to
damage them.
10. Apply a small amount of anti-seize compound to the threads of
the exhaust port studs. On motorcycles with mid controls, it may
be necessary to remove the front eyelet of the brake actuation
rod, this will allow the brake pedal to swing up and out of the
way. Wrap the pedal with a rag to prevent scraping the heat
shield and use some means of holding the brake pedal in the
upright position (See Picture 5, below.)
11. Install the header by carefully inserting the rear head pipe and
flange first then rotate the header forward and up to insert the
front head pipe and flange.
12. Install the flange nuts to hold the header in place, but do not fully
tighten yet.
13. Pull the header outward slightly and install the two carriage
bolts to the to the slotted channels in the back of the header
(See Picture 6., above right)
14. Push the header back toward the mounting bracket. Make sure
the carriage bolts go through the holes in the mounting bracket.
15. Install the flange nuts to the carriage bolts but do not fully
tighten yet.
16. Tighten the exhaust port flange nuts followed by the mounting
bracket flange nuts.
17. Adjust alignment of the front and rear heat shields and tighten
the clamps.
18. Apply a small amount of anti-seize compound to the threads of
the oxygen sensors and re-install. Be careful not to get any anti-
seize compound on the tip of the sensor, as this may affect its
functionality.
19. Reconnect the front and rear oxygen sensors on EFI equipped
bikes.
20. Apply Loctite to the front brake rod eyelet and reinstall. Torque
to 120-180 in*lbs.
21. Inspect the exhaust system and make sure there is sufficient
space between the exhaust system and motorcycle accessories.
22. Thoroughly clean the exhaust system to remove any fingerprints
or oil before the motorcycle is started
Picture 5
Picture 6 Picture 4