Harley Davidson Touring: Exhaust Review and How-to

This article applies to Harley Davidson Touring models (2000-2015).

Over the years, the intake and exhaust systems on Harley big twins have become restricted to meet EPA noise and smog law requirements. As a result, much of the traditional pushrod V-Twin sound is muted and performance suffers. Fortunately, the aftermarket is booming with replacement exhaust systems to restore your bike's bellowing roar. With improved sound, increased performance, and refined aesthetics, it is no wonder why an exhaust system is the #1 modification performed by Harley owners. If you are still riding around with your stock exhaust, but have the itch for a new system, this article will give you an outline of the installation procedure as well as a brief review of several exhausts for Harley Davidson Touring models.

Table of Contents

• How to Replace Your Exhaust
• Featured Video
• Exhaust Review

How to Replace Your Exhaust

Aftermarket exhaust systems for Harley bagger can be grouped into two broad categories: 1) Slip-ons, and 2) Full systems. A slip-on replaces just the mufflers, while the full system includes the head pipes, crossovers, and of course the mufflers, and sometimes dramatically changes the look of the bike. Installing either starts out the same, but with the slip-ons, you can skip a lot of the middle steps.

Step 1 – Remove saddlebags

Removing the saddlebags will free up additional room to work around the exhaust system to aid in muffler removal.

Step 2 – Remove mufflers

With the saddlebags removed from the bike, the mufflers can now be removed. Each muffler has an exhaust clamp securing it to the head pipe as well as a small muffler support bracket.

• Using a 9/16" socket or wrench, loosen the muffler clamp. In some cases a bit of penetrating oil can help to breakdown any corrosion that has developed on the clamp.
• Remove the muffler bracket bolts using a 1/2" socket or wrench.
• With the clamp loosened and the bracket bolts removed, the muffler can be slid off of the head pipe.
• Work the muffler off with a twisting and pulling motion. The mufflers have a very snug fit, so do not be discouraged if they seem overly tight.
• Repeat procedure for the other muffler.

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If installing a set of slip-on mufflers, skip to Step 8.

Step 3 – Remove crossover pipe

The crossover pipe is attached to the head pipe with an exhaust clamp similar to that of the muffler clamps. Additionally, a small bracket just in front of the rear wheel supports the pipe.

• Using a 5/8" socket or wrench, loosen the exhaust clamp.
• Remove the support bracket using a 1/2" wrench before sliding the bracket off of the pipe.
• With the bracket removed and clamp loosened, remove the crossover pipe using a twisting motion.

Step 4 – Remove right floorboard and exhaust heat shields

To allow for removal of the exhaust head pipe, the right floorboard should be removed. Similarly, the entire footrest assembly can be removed from the frame. The heat shields must also be removed from the exhaust.

• Using a 3/16" hex (Allen) wrench and 7/16" wrench or socket, remove the bolts securing the floorboard to the footrest bracket. Set floorboard aside.
• The heat shields are held in place with worm-type hose clamps. Using a 5/16" nut driver or socket, undo the hose clamps on the backside of the head pipe and remove the shields.

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Step 5 – Disconnect oxygen sensors (if applicable)

Underneath the side cover are the oxygen sensor harness plugs that must first be disconnected before removing the head pipe.

• With the side cover removed, disconnect the oxygen sensor plugs. With the plugs disconnected, cut any wire ties securing the sensor wiring to the frame and route the wires free from the bike.

Step 6 – Remove head pipe

• Remove the head pipe support bolt using a 9/16" socket. The bolt has a tendency to move upwards as the nut is being loosened, so use a small object like a screwdriver or extension to hold the bolt down while the nut is removed.

• Remove the head pipe flange nuts from each cylinder using a 1/2" wrench and socket as needed.
• The head pipe can now be removed. In some instances, the floorboard support bracket may need to be removed to allow for additional movement of the exhaust.
• Be sure to retrieve the old crush gaskets from the exhaust ports.

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Step 7 – Install new exhaust head pipe

After the stock exhaust system has been removed, any old components can be transferred to the new system and re-installed onto the bike.

• Remove the oxygen sensors from the stock exhaust using a 9/16" wrench and install them into the new system (if applicable). Apply a small amount of anti-seize paste to the threads before installation.
• If your new exhaust does not come with flanges, remove the circlips from the stock exhaust with a set of pliers. Slide the flanges off of the old pipe an onto the new exhaust and refit the circlips.
• Many exhaust systems come with a new support bracket to hold head pipe in place. If applicable, remove the support bracket using a 1/4" hex (Allen) key. Install the new support bracket and torque the fasteners to 13-16 ft/lbs.

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• Install new crush gaskets into each exhaust port, making sure they are fully seated.
• Slide the new head pipe into place and fasten the exhaust flanges. Tighten the exhaust flange nuts evenly and to a torque of 60-80 in/lbs. Additionally, tighten the head pipe support bracket bolt(s) as indicated in the exhaust manufacturer's instructions.
• Route the oxygen sensor wiring back to their respective plugs and secure with wire ties as necessary.
• Attach and tighten any included exhaust heat shields.
• Reattach the footboard and footboard support brackets if necessary.

Step 8 – Install new muffler(s)

Whether swapping out the stock mufflers or installing a new system, the final step is to position the new muffler(s) onto the head pipe.

• Slide the muffler(s) onto the head pipe assembly along with the necessary exhaust clamp(s).
• If necessary, swap the muffler brackets from your old mufflers to the new mufflers before fastening the muffler to the support bracket.
• With the muffler(s) in place, tighten the exhaust clamp(s) to 45-60 ft/lbs and fully tighten the muffler bracket bolts.

Step 9 – Wipe the exhaust clean, start bike, and check for exhaust leaks

After installation has been completed, take a few moments to wipe down the exhaust system. This will ensure that any grease, oils, or other contaminants are not burned into the pipes when the engine is started. With the exhaust system clean, start the engine and listen as well as feel for exhaust leaks at each joint and near the head pipe flanges. If no leaks are present, re-install the saddlebags and side cover.

Featured Video: How to Change Touring Model Exhaust