S&S Cycle Power Tune Sport Exhaust System for 2014 Harley-Davidson Sportster Models (PN 550-0379 and 550-0380) - Manual (Page 2)

Removal of stock exhaust system:
1. Secure the motorcycle to prevent tipping during installation.
2. Remove the stock heat shields.
3. Unplug the front and rear oxygen sensors.
4. Remove the bolts that hold the mufflers to the crossover tube
bracket. This bracket will not be re-used.
5. Remove the carriage bolt that holds the rear head pipe clamp to
the belt cover.
6. Remove the exhaust port flange nuts from each head pipe and set
aside, these will be re-used.
7. Remove the exhaust pipe and muffler assembly.
8. Remove the circlips and flanges from the stock exhaust system
using a snap ring pliers.
9. Inspect circlips for damage or deformation, replace if necessary.
10. Remove the stock oxygen sensors, these will be re-used
11. Remove the drive belt cover.
12. Remove the clip and pin holding the rear brake actuator rod to the
master cylinder.
13. Remove the exhaust bracket from underneath the belt cover, this
will not be re-used.
14. Remove the stock exhaust port gaskets.
Installation of S&S Power Tune Sport Exhaust
1. Remove header and heat shields from protective foam packaging.
Place them in a non-abrasive surface. Unpack the end cap kit.
2. Apply a small amount of Loctite to the supplied screws and install
the end caps to the ends of the heat shields (See Picture 1). Keep
the remaining Loctite, it will be needed again in later steps
3. Using a marker, place a mark on the edge of the heat shield exactly
at the middle of each heat shield hold down clip (See Picture 2,
below left.) This is done to easily locate the clips in the heat shields
at the time of assembling the heat shields onto the head pipe.
Slide the heat shields over the header starting at the tail end of the
header.
4. Install each hose clamp by feeding the tail end of the clamp into
the heat shield clips. Take note of clamp screw head direction. The
screw head must be accessible when the exhaust system is installed
on the motorcycle. Do not fully tighten at this time.
5. Install the exhaust flanges and circlips onto the front and rear head
pipe.
6. Install the supplied mounting bracket to the motorcycle
transmission (See Picture 3). Apply Loctite to the two 3/8" Allen
head bolts that were previously removed. Torque to 32 ft*lbs. Make
sure the brake actuation rod is placed through the bracket. and re-
insert into the master cylinder.
7. Install the drive belt cover using the original hardware. Torque the
3/8” Allen head bolts to 32 ft*lbs and the 1/4” Allen head bolts 85-115
in*lbs. The stock rear exhaust pipe clamp, bracket, and carriage bolt
are not needed with the new header.
8. Install the supplied exhaust port gaskets taking care not to damage
them.
9. 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 move the brake pedal to make room for installation
of the header. 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 4).
Kit Contents:
Exhaust System Kit
• Header assembly
• Heat shields
• Header attachment bracket
• Exhaust port gaskets
• Oxygen sensor adapters
• 1/2" flat washers
• 3/8" jam nuts
• Loctite 262
End cap kit (packaged
separately)
• 2 end caps
• 4 mounting screws
• Loctite® 262
Tools Needed:
• 1/2" socket and ratchet with
extensions
• 1/2" wrench
• 5/8" wrench
• 7/8" wrench
• 3/16" Allen wrench
• 3/8" Allen wrench
• Snap ring pliers
2
Picture 2
Picture 3
Picture 1