How To Put On Slip On Exhaust On Harley: A Step-by-Step Guide

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So, you’re looking to upgrade your Harley-Davidson with a new slip-on exhaust? Excellent choice! It’s one of the most popular and impactful modifications you can make, instantly changing the sound and often boosting performance. This guide will walk you through the entire process, from choosing the right exhaust to the final bolt tightening. We’ll cover everything you need to know to confidently tackle this project in your own garage.

Don’t worry if you’re not a seasoned mechanic. This is a project most riders can handle with basic tools and a little patience. We’ll break down each step clearly, providing helpful tips and avoiding jargon. Before you know it, you’ll be enjoying the rumble of your new exhaust on the open road. Let’s get started!

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Choosing the Right Slip-on Exhaust for Your Harley

Before you even touch a wrench, you need to select the right slip-on exhaust for your Harley-Davidson. This is a crucial step, as the exhaust you choose will significantly impact the sound, performance, and aesthetics of your bike. Here’s what you should consider:

1. Compatibility

The most important factor is compatibility. Make sure the exhaust is designed for your specific Harley-Davidson model and year. Check the manufacturer’s website or the product description to confirm. Exhaust systems are often designed for specific engine configurations (e.g., Twin Cam, Milwaukee-Eight) and frame styles. Using an incompatible exhaust can lead to fitment issues and potential damage to your motorcycle.

2. Sound

The sound of your exhaust is a personal preference. Some riders prefer a deep, throaty rumble, while others prefer a more aggressive, raspy tone. Listen to sound clips online (YouTube is your friend!) to get an idea of how different exhausts sound on your model Harley. Consider the legal noise regulations in your area, as some exhausts are louder than others. Many manufacturers offer different baffle options to adjust the sound level. (See Also: Won Hundred Willow Slip On Sneakers )

3. Performance

While slip-on exhausts typically provide modest performance gains, they can still improve horsepower and torque, especially when combined with other modifications like a high-flow air intake and a fuel management system. Look for exhausts that are designed to optimize exhaust flow. Some manufacturers provide dyno charts to demonstrate performance improvements. Remember that the performance gains from a slip-on exhaust alone may not be as significant as a full exhaust system.

4. Style and Aesthetics

Slip-on exhausts come in various styles, including:

Shorty: Compact and often louder, giving a more aggressive look.
Long: Classic look, often with a deeper tone.
Slash-cut: Angled cut, adding a touch of style.
Turnout: Exhaust angles away from the bike.
Chrome: Classic and shiny look.
Black: Modern and sleek.
Brushed Metal: Adds a rugged look.

Choose an exhaust that complements the overall look of your Harley-Davidson. Consider the finish (chrome, black, stainless steel) and the design to ensure it matches your personal style.

5. Build Quality and Materials

Exhausts are exposed to extreme heat and the elements, so build quality is essential. Look for exhausts made from high-quality materials like stainless steel or aircraft-grade aluminum. Check the welds and ensure the exhaust is well-constructed. A durable exhaust will last longer and maintain its appearance over time. Consider the manufacturer’s warranty as an indicator of their confidence in the product. (See Also: Will Two Brothers Slip On Exhaust Work For Rebel 300 )

6. Price

Slip-on exhaust prices vary widely. Set a budget before you start shopping. While you don’t necessarily need to buy the most expensive exhaust, consider the value for money. A slightly more expensive exhaust from a reputable brand may offer better performance, sound, and build quality. Compare prices from different retailers to find the best deal.

7. Brand Reputation

Research different exhaust brands. Read reviews from other Harley-Davidson owners to get feedback on the quality, sound, and customer service of the manufacturer. Some popular and well-regarded brands include:

Vance & Hines
Screamin’ Eagle (Harley-Davidson)
Cobra
Bassani
Rinehart Racing
Two Brothers Racing

These brands generally offer a good balance of quality, performance, and style.

Tools and Materials You’ll Need

Gathering the right tools and materials is crucial for a smooth installation. Here’s a comprehensive list: (See Also: Will You Lose Low End With M4 Slip On Fz07 )

New Slip-On Exhaust: Make sure it’s the right one for your bike!
Socket Set: Metric sizes are typically used on Harley-Davidsons. Include the sizes needed for your exhaust and any necessary hardware.
Wrench Set: Open-end and box-end wrenches, again, in metric sizes.
Torque Wrench: Essential for tightening bolts to the correct specifications.
Penetrating Oil (e.g., PB Blaster): To help loosen stubborn bolts.
Anti-Seize Compound: To prevent future corrosion and make removal easier.
Gloves: Protect your hands.
Safety Glasses: Protect your eyes.
Jack or Lift: To safely raise and stabilize the motorcycle. A motorcycle lift is ideal, but a jack and jack stands will work.
Wheel Chocks: To prevent the motorcycle from rolling.
Shop Towels or Rags: For cleaning up spills and wiping parts.
Optional: Exhaust gasket (check if your new exhaust requires it, and if it’s included).
Optional: Impact Wrench (for faster bolt removal, but be careful not to overtighten).

Step-by-Step Installation Guide

Now, let’s get down to the actual installation. Follow these steps carefully, and you’ll be enjoying your new exhaust in no time:

1. Prepare Your Motorcycle

Safety First: Ensure your motorcycle is on a level surface.
Cool Down: Let the engine cool completely. Working on a hot exhaust can lead to burns.
Wheel Chocks: Place wheel chocks in front and behind the rear wheel. This will prevent the bike from rolling during the process.
Lift (If Necessary): If you need more access, lift the motorcycle using a jack or lift. Secure the bike with jack stands if you’re using a jack. Ensure the bike is stable.
Protect Surfaces: Cover any painted surfaces near the exhaust with shop towels to prevent scratches.

2. Remove the Old Exhaust

Locate the Exhaust Bolts: Identify the bolts that secure the stock slip-on exhaust to the head pipes and the bracket that attaches it to the frame.
Penetrating Oil: If the bolts look rusty or corroded, spray them with penetrating oil and let it sit for a few minutes. This can significantly ease removal.
Loosen the Bolts: Use the appropriate socket or wrench to loosen the bolts. Be careful not to strip the bolt heads. If a bolt is stuck, try tapping it gently with a hammer or using a breaker bar.
Remove the Exhaust: Once the bolts are loose, carefully remove the old slip-on exhaust. You may need to wiggle it slightly to detach it from the head pipes.
Inspect the Gasket (If Applicable): If your old exhaust used a gasket where it connects to the head pipe, inspect its condition. If it’s damaged or worn, replace it with a new one. Some new exhausts include a new gasket.

3. Prepare the New Exhaust

Unpack and Inspect: Carefully unpack your new slip-on exhaust and inspect all components for any damage.
Read the Instructions: Review the manufacturer’s instructions thoroughly. They may have specific steps or recommendations for your exhaust model.
Apply Anti-Seize: Apply anti-seize compound to the threads of the bolts that will secure the new exhaust. This will prevent corrosion and make future removal easier.

4. Install the New Exhaust

Attach to Head Pipes: Slide the new slip-on exhaust onto the head pipes. Align the exhaust with the mounting points.
Install Mounting Hardware: Install the bolts that secure the exhaust to the head pipes and the frame bracket. Don’t tighten them completely yet; leave them slightly loose so you can make adjustments.
Align and Adjust: Make sure the exhaust is aligned correctly and doesn’t interfere with any other parts of the motorcycle, like the swingarm or rear tire. Adjust the position as needed.
Tighten the Bolts: Once you’re satisfied with the alignment, tighten the bolts to the manufacturer’s recommended torque specifications. Use a torque wrench to ensure proper tightening. Over-tightening can damage the exhaust or the motorcycle’s components. Under-tightening can lead to leaks and vibration.
Check for Leaks: After tightening the bolts, start the engine and let it run for a few minutes. Listen for any exhaust leaks. If you hear a leak, check the connections and tighten the bolts further, but don’t over-tighten them.
Install any included hardware: Some exhausts come with heat shields or other hardware that needs to be installed. Follow the manufacturer’s instructions.

5. Final Checks and Finishing Touches

Inspect the Installation: Double-check all bolts and connections to ensure they are secure.
Clean the Exhaust: Wipe down the exhaust with a clean rag to remove any fingerprints or smudges.
Test Ride: Take your Harley-Davidson for a short test ride to make sure everything is working correctly and that you’re happy with the sound and performance.
Re-torque Bolts: After the first ride, allow the exhaust to cool completely. Then, re-torque all the bolts to ensure they haven’t loosened.
Fuel Management (If Necessary): Depending on the exhaust and your bike’s modifications, you may need to adjust the fuel management system. Some exhausts come with a fuel management module, while others require a professional tune. Consult the manufacturer’s recommendations.

Troubleshooting Common Problems

Even with careful planning, you might encounter a few hiccups during the installation. Here’s how to address some common issues:

Bolt Stripping: If you strip a bolt head, try using a bolt extractor tool. If the bolt is completely stripped, you may need to drill it out and re-tap the threads.
Exhaust Leaks: Exhaust leaks are often caused by loose bolts or a damaged gasket. Check all connections and tighten the bolts to the correct torque specifications. Replace the gasket if necessary.
Difficulty Removing Old Bolts: Use penetrating oil and let it soak. A breaker bar can provide extra leverage. If the bolt is severely stuck, you may need to use heat (carefully!) or cut the bolt off.
Fitment Issues: If the exhaust doesn’t fit properly, double-check that you have the correct model for your Harley-Davidson. Contact the exhaust manufacturer or the retailer for assistance.
Excessive Noise: If the exhaust is excessively loud, check for leaks and ensure all baffles or silencers are installed correctly. Consider adding a quieter baffle if the noise is still too loud.
Performance Issues: If you experience a loss of performance, check for exhaust leaks and ensure the fuel management system is properly tuned (if applicable).

Safety Precautions

Safety should always be your top priority. Here are some important safety precautions to follow:

Eye Protection: Always wear safety glasses when working on your motorcycle.
Gloves: Wear gloves to protect your hands from cuts, abrasions, and heat.
Proper Ventilation: Work in a well-ventilated area to avoid inhaling exhaust fumes.
Hot Surfaces: Be careful of hot surfaces, such as the exhaust pipes and engine components. Let the engine cool down completely before working on the exhaust.
Secure the Motorcycle: Ensure the motorcycle is stable and secure before starting any work. Use wheel chocks and a jack or lift if necessary.
Torque Specifications: Always use a torque wrench and tighten bolts to the manufacturer’s recommended torque specifications.
Fuel Lines: Be extremely careful when working near fuel lines. Avoid spilling fuel, and clean up any spills immediately.
Fire Extinguisher: Keep a fire extinguisher nearby in case of a fire.
If in Doubt: If you’re unsure about any step of the process, consult a qualified motorcycle mechanic.

Maintaining Your New Exhaust

Proper maintenance will help your new slip-on exhaust last for years and maintain its appearance. Here are some tips:

Regular Cleaning: Clean the exhaust regularly with a mild soap and water solution. Avoid using harsh chemicals or abrasive cleaners.
Polishing (If Applicable): If you have a chrome or polished exhaust, polish it regularly to maintain its shine.
Inspect for Damage: Periodically inspect the exhaust for any signs of damage, such as dents, cracks, or rust.
Check Connections: Regularly check the bolts and connections to ensure they are secure.
Lubricate Moving Parts: If your exhaust has any moving parts, such as a baffle adjustment mechanism, lubricate them periodically.
Protect from the Elements: If you store your Harley-Davidson outdoors, consider using an exhaust cover to protect the exhaust from the elements.

Fuel Management Considerations

While a slip-on exhaust alone may not always require fuel management adjustments, it’s something to consider. Here’s why:

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Air/Fuel Ratio: Changing the exhaust flow can alter the air/fuel ratio of your engine. If the ratio becomes too lean (too much air, not enough fuel), it can lead to performance issues, overheating, and potential engine damage. If it’s too rich, it can cause poor fuel economy and potentially foul spark plugs.
Stock Tuning: Many Harley-Davidsons are tuned from the factory to run a bit lean to meet emissions standards. A freer-flowing exhaust can exacerbate this leanness.
When to Consider Fuel Management: You should strongly consider fuel management if you’ve also installed a high-flow air intake or if you experience any performance issues after installing the slip-on exhaust.
Fuel Management Options:

Fuel Tuners: These are add-on modules that modify the signals sent to the fuel injectors, adjusting the fuel delivery. Popular brands include Dynojet Power Vision, Vance & Hines Fuelpak, and others.
ECU Remapping: This involves reprogramming the engine control unit (ECU) to optimize the fuel map. This usually requires a dyno and a professional tuner.

Professional Tuning: For optimal performance and reliability, consider having your Harley-Davidson professionally tuned after installing a slip-on exhaust and/or air intake. A professional tuner can fine-tune the fuel map to match your specific modifications and riding style.
Manufacturer Recommendations: Always follow the exhaust manufacturer’s recommendations regarding fuel management. Some exhausts are designed to work without any adjustments, while others may require a specific fuel tuner.

Final Verdict

Installing a slip-on exhaust on your Harley-Davidson is a rewarding project that can significantly enhance the sound and aesthetics of your bike. By following the steps outlined in this guide, you can confidently tackle this modification in your own garage. Remember to prioritize safety, choose the right exhaust for your model, and take your time. Enjoy the process, and most importantly, enjoy the ride! With the right tools, some patience, and attention to detail, you’ll be hitting the road with a better-sounding and potentially better-performing Harley-Davidson. Remember to re-torque the bolts after the first ride, and consider the need for fuel management adjustments. Happy riding!