How to Install Exhaust on Harley Davidson: A Step-by-Step Guide for Riders

Thinking about upgrading your Harley’s exhaust? You’re not alone. Many riders want to enhance their bike’s sound and performance, but the installation process can seem daunting.

Key Takeaways

• Essential Tools: Gather specific tools such as wrenches, a socket set, a torque wrench, and protective gear to ensure a smooth installation process for your Harley Davidson exhaust.
• Prep the Motorcycle: Prioritize safety by wearing protective gear, working in a well-ventilated area, and properly prepping your bike before removing the old exhaust.
• Step-by-Step Removal: Follow a systematic approach to detach the old exhaust, including disconnecting the battery, loosening clamps, and inspecting fittings for damage.
• Accurate Installation: Align the new exhaust precisely with the header pipes and secure it using manufacturer-specified torque to prevent leaks and ensure optimal performance.
• Final Checks: Inspect for exhaust leaks, ensure fittings are tight, and check clearances around components post-installation to confirm safety and performance before taking a test ride.

Tools and Materials Needed

Installing an exhaust on your Harley Davidson requires specific tools and materials. Having these on hand makes the process smoother and more efficient.

Essential Tools

1. Wrenches: Use a combination of metric and standard wrenches for various nut sizes.
2. Socket Set: A complete socket set, including extensions and ratchets, simplifies accessing tight spaces.
3. Screwdriver Set: Both flathead and Phillips screwdrivers are necessary for removing and securing components.
4. Torque Wrench: A torque wrench ensures that you tighten bolts to the manufacturer’s specifications, preventing any damage.
5. Pliers: Needle-nose and regular pliers aid in gripping small components and removing clips.
6. Cutting Tool: A cutting tool or pipe cutter may be necessary for adjusting the length of exhaust pipes.
7. Protective Gear: Safety glasses and gloves protect you during the installation process.

1. Slip-On Exhausts: Slip-ons provide an easy upgrade, requiring minimal modifications. Brands like Vance & Hines and Screamin’ Eagle offer popular options.
2. Full Systems: Full exhaust systems replace the entire setup. Consider systems from Rinehart Racing or Bassani for improved performance.
3. Dual Exhausts: For those who want a distinct sound, dual exhaust setups deliver powerful sound and increased horsepower.
4. Header Kits: Header kits often optimize your bike’s performance and are available from several manufacturers, including Cobra.
5. Custom Exhausts: If you’re looking for a unique sound and style, custom exhausts can be tailored to your preferences. Local shops or specialized builders provide this service.

Gather these tools and materials before starting your exhaust installation to ensure a hassle-free experience.

Preparing Your Harley Davidson

Preparing your Harley Davidson for an exhaust installation ensures a smooth process. Follow these steps to get your bike ready.

Safety Precautions

Safety comes first during any motorcycle maintenance task. Wear protective gear, including gloves, safety glasses, and sturdy clothing. Keep a fire extinguisher nearby in case of unexpected issues. Work in a well-ventilated area to avoid inhaling harmful fumes. Ensure your bike is stable on a flat surface before you begin.

Removing the Old Exhaust

Removing the old exhaust system requires a systematic approach.

1. Gather Tools: Have your tools ready—socket set, wrenches, and pliers will be essential.
2. Disconnect the Battery: Remove the negative terminal from the battery to prevent any electrical shorts.
3. Loosen Fasteners: Start by loosening the exhaust clamps and bolts holding the old exhaust in place. Use penetrating oil if the bolts are rusted.
4. Remove Heat Shields: If your Harley has heat shields, gently unscrew and remove them.
5. Take off the Exhaust: Carefully slide the old exhaust off the mounting points. If needed, tap gently with a rubber mallet to loosen stubborn parts.
6. Inspect Fittings: Check the exhaust ports and hangers for any damage or corrosion before installing the new exhaust.

Completing these steps prepares your Harley for the new exhaust system effectively.

Installing the New Exhaust

Installing a new exhaust on your Harley Davidson enhances both sound and performance. Follow these steps for a successful installation.

Step-by-Step Installation Process

1. Gather Tools: You’ll require a socket set, wrenches, screwdrivers, torque wrench, and possibly a rubber mallet. Ensure you have all tools before starting.
2. Remove Old Exhaust: Start by removing mounting bolts from the headers. Use the appropriate socket size to avoid stripping. Slide the old exhaust off the mounting brackets.
3. Clean Surfaces: Inspect the header pipes for debris or rust. Use a wire brush to clean the mounting surfaces thoroughly. This ensures a proper seal for the new exhaust.
4. Position New Exhaust: Align the new exhaust system with the header pipes and mounting points. Make sure it sits evenly and fits snugly.
5. Secure the Exhaust: Begin fastening bolts from the headers to the mufflers. Hand-tighten first, then use a torque wrench to secure to manufacturer specifications.
6. Reconnect Components: Reattach any heat shields and rewire any disconnected components. Ensure everything aligns correctly and is secure.
7. Check Installation: Inspect the installation for any loose fittings or misalignments. A tight fit prevents exhaust leaks.
8. Start the Engine: Start your Harley and listen for any unusual sounds. Look for exhaust leaks around the joints. Address any issues before hitting the road.

• Stuck Bolts: If bolts are rusted, apply penetrating oil and let it soak for several minutes. Use a breaker bar if necessary for extra leverage.
• Misalignment: If the exhaust doesn’t align, loosen the bolts slightly and adjust the position. Once aligned, retighten bolts gradually.
• Exhaust Leak: If you hear a leak, check joints for proper sealing. You may need to replace gaskets if they’re worn.
• Heat Shield Fitment: If heat shields don’t fit correctly, double-check the exhaust positioning and adjust as needed.

With these steps in mind, you’ll enjoy the satisfaction of a successful exhaust installation on your Harley Davidson.

Finalizing the Installation

After completing the installation steps, focus on final checks to ensure everything functions properly. This stage is crucial for confirming no issues exist that could affect performance or safety.

Checking for Leaks

Inspect connections and joints for exhaust leaks. Start your motorcycle and let it idle for a few minutes. Listen for any unusual sounds or hissing noises, which can indicate leaks. For a more thorough check, feel around the joints with your hand. If you detect any escaping air, re-tighten the bolts or clamps in that area. You can also use soapy water to expose leaks; apply it to the connections, and watch for bubbles forming. If leaks persist, you might need to re-align or replace gaskets.

Properly Securing the Exhaust

Make sure the exhaust is securely fastened. Double-check all bolts and clamps against each manufacturer’s specifications. Tighten them gradually in a crisscross pattern to ensure even pressure distribution. Inspect any heat shields to confirm they’re mounted correctly and snugly. Look for clearance issues around the frame and other components. Finally, take a quick test ride to listen for rattles, vibrations, or loose connections. Adjust as necessary to achieve a stable and secure installation.

Conclusion

Installing a new exhaust on your Harley Davidson can be a rewarding experience that enhances both the sound and performance of your ride. With the right tools and a little patience you can transform your bike and enjoy the fruits of your labor.

Remember to take your time during the installation process and double-check everything to avoid any issues down the road. Once you’re done take that test ride and feel the difference. Your Harley’s new voice is just waiting to be unleashed so get out there and enjoy the open road!

Frequently Asked Questions

What are the benefits of upgrading my Harley’s exhaust system?

Upgrading your Harley’s exhaust system can enhance performance by improving airflow, resulting in more power and better fuel efficiency. It also provides a deeper, more appealing sound that many riders desire. Additionally, a new exhaust can improve the overall aesthetic of your bike.

What tools do I need to install a new exhaust on my Harley?

Essential tools for installing a new exhaust include a socket set, wrenches, screwdrivers, a torque wrench, a rubber mallet, and heat-resistant gloves. It’s also helpful to have penetrating oil for stuck bolts and a wire brush for cleaning surfaces.

How do I safely remove the old exhaust?

To remove the old exhaust, first, ensure the bike is cold and on a stable surface. Disconnect any components attached to the exhaust, apply penetrating oil to stuck bolts, and carefully unscrew and remove the old exhaust system. Clean the mounting surfaces for the new installation.

How do I ensure the new exhaust is installed properly?

Position the new exhaust carefully and secure it according to the manufacturer’s instructions. Reconnect any components, and double-check that bolts are properly tightened. Perform a final check for alignment and clearance before taking a test ride.

What are common problems during exhaust installation?

Common problems include stuck bolts, misalignment of the exhaust, and exhaust leaks. To avoid issues, ensure all bolts are lubricated, measure alignment before securing, and use soapy water to check for leaks after installation.

How can I check for exhaust leaks after installation?

To check for exhaust leaks, listen for unusual sounds while the engine is running, feel for escaping air around connections, and use soapy water to see if bubbles form when sprayed on the joints. Address any detected leaks promptly.

Why is it important to check for proper clearance post-installation?

Checking for proper clearance after installation is crucial to prevent contact between the exhaust and other bike components. This ensures that heat shields function correctly and reduces the risk of overheating or damage to surrounding parts.

What should I do if I hear rattling or vibrations after installation?

If you experience rattling or vibrations after installation, stop and inspect all bolts and clamps to ensure they are secure. Check for improper alignment or loose components, and perform a test ride to identify and address any persistent issues.