The steps to install the exhaust on a Harley Ultra Classic are very basic.
Installing the exhaust on your Harley Davidson Ultra Classic is a rather simple task, with the use of the correct tools. It is also a necessity when trying to optimize the fuel economy of your Harley. You may need to reinstall the stock exhaust for your Ultra Classic if the previous owner installed an aftermarket set of exhaust and you desire to return the bike to stock condition. Once you have completely removed the old set of exhaust, you are set to install the new exhaust.
1. Install new gaskets in the rear and front cylinder head exhaust ports. The tapered side of the gasket should be facing towards you. Install the gasket by pushing it all the way into the port with your fingers.
2. Install and tighten the transmission exhaust bracket onto the transmission side door. Tighten with an Allen wrench.
3. Install the front header pipe exhaust flange onto the front cylinder head by simply pushing it into place. Begin threading the flange nuts onto the cylinder head studs by hand.
4. Slide the transmission exhaust bracket clamp over the other end of the front header pipe. You may have to tighten the clamp with channel lock pliers. Tighten the clamp bolt with your fingers just enough to hold it in position.
5. Slide a new TORCA clamp onto the front header pipe approximately an inch away from the transmission exhaust bracket clamp.
6. Install one end of the rear header pipe onto the rear cylinder head located on the bike. Slide the other end onto the front header pipe through the TORCA and transmission exhaust bracket clamps. Install the rear header pipe flange by pushing it into place. Begin threading the flange nuts on the cylinder head studs by hand. Move the already installed TORCA clamp directly over where the front and rear header pipes are connected.
7. Install TORCA clamps at the two remaining open ends of the rear header pipe. The TORCA clamp that connects to the crossover pipe — the pipe that crosses over to the opposite side of the bike — is a special clamp in that it has a slot for the exhaust support bracket.
8. Slide the right muffler onto the rear header pipe. Loosely tighten the screws and lock washers that connect the muffler to the bottom of the saddlebag supports. Move the already installed TORCA clamp directly over where the rear header pipe and right side muffler are connected.
9. Install the crossover pipe onto the remaining end of the rear header pipe — located directly above the starter. Move the already installed TORCA clamp directly over where the rear header pipe and the crossover pipe are connected; ensuring the clamp slides into the slot located on the exhaust support bracket.
10. Slide another TORCA clamp onto the open end of the crossover pipe. Connect the left side muffler to the crossover pipe. Move the already installed TORCA clamp directly over where the left side muffler and crossover pipe are connected. Slightly tighten the bolts of the clamp.
11. Tighten the exhaust into place. Tighten the top nut of the front cylinder head exhaust flange to 9 to 18 inch-pounds with a torque wrench. Tighten the bottom nut of the same flange to 100 to 120 inch-pounds. Re-tighten the top nut to 100 to 120 inch-pounds. Repeat these steps for the rear cylinder head exhaust flange. Tighten the transmission exhaust bracket bolt to 60 to 96 inch-pounds. Tighten the bolts of both the right and left mufflers with a standard wrench. Tighten the four TORCA clamps to 45 to 60 foot-pounds with the torque wrench in the following order: crossover pipe to left side muffler, rear header pipe to right side muffler, front header pipe to rear header pipe and rear header pipe to crossover pipe.