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HARLEY-DAVIDSON® TOURING

TRUE DUAL INSTALLATION INSTRUCTIONS

PART# 7015-7115

EXHAUST SYSTEM REMOVAL

READ ALL INSTRUCTIONS BEFORE BEGINNING

1. Remove both saddlebags and side covers from the motorcycle.

2. Remove seat and place it away from the work area; disconnect battery.

3. Cover the primary housing, transmission top, and end cover near the head pipe to prevent damage.

4. Remove the bolt for the passenger floorboard that attaches it to the frame.

5. Remove the right side rider floorboard and support brackets. Loosen muffler clamps; remove the support bolts located at the rear upper portion of the muf-flers. Remove mufflers from the head pipes. Unscrew clamps on the factory heat shields and remove heat shields from the head pipes.

6. Unplug both O² sensors. Cut and remove zip strip that holds the front O² sensor wire to the frame. Loosen clamp on the rear exhaust pipe; remove the left side pipe while leaving the crossover pipe in place.

7. Remove the support tab that is attached to the support bracket located near the starter; save tab for reassembly.

8. Loosen the P-clamp on the right side of the motorcycle, near the transmission end cover; remove the carriage bolt and nut. See Figure 1.

9. Remove nuts from the flanges located at the cylinder heads. Remove the right side pipe as one unit. Remove stock crossover mounting bracket located above the starter.

10. Using snap ring pliers, carefully remove circlips on each pipe inlet; remove flange. See Figure 2. NOTE: Replace circlips if damaged or bent. Check condition of exhaust port gaskets and replace with H-D P/N 65324-83A.

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Thank you for purchas ing RUSH . We strive for excellence and take pride in making the best exhaust for your Harley-Davidson®. We take our full systems to an all new level in the exhaust industry! Our full systems come standard with ceramic coating on both the inside and outside of the head pipe, providing superior heat reduction and quality looks for years to come.

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BEFORE INSTALLATION PLEASE READ ALL INSTRUCTIONS

1. Remove header and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark outside edge of each heat shield to show location of mounting clips that hose clamps will loop through. See Figure 3.

2. Slide flanges on head pipes with recessed area of flange facing pipe inlet. See Figure 2. Reinstall circlips using snap ring pliers. Using a 7/8” wrench, carefully remove O² sensors from stock head pipes. NOTE: Replace circlips if damaged or bent.

3. Apply anti-seize on O² sensors before installation, then install. NOTE: Be care-ful not to get any anti-seize on the head of the sensor as this may cause the sensor to malfunction.

4. Install BRKT-003 supplied with the system. See Figure 4. 5. Remove stock support bracket located below transmission end cover and install

BRKT-002 supplied with the system. 6. Mount right side rider floorboard supports with WASHER #5 and BOLT #10.

Place spacers between frame and support brackets. Do not tighten. 7. Install right head pipe by sliding flange up to cylinder head; tighten nuts by

hand. 8. Slide P-clamp on rear of head pipe and mount to support bracket using

WASHER #4 and stock carriage bolt and nut. See Figure 1. 9. Slide muffler clamp on muffler inlet and install muffler on head pipe. Do not

tighten. Install mounting bolts into rear muffler support bracket. Do not tighten.

10. Starting at front of right head pipe, tighten all hardware while maintaining proper alignment of exhaust system.

11. Reconnect O² sensors; install new ZIP STRIP to hold O² sensor wires. 12. Install header support tab on support bracket located above starter. Do not

tighten. See Figure 4. 13. Install left head pipe by sliding flange up to cylinder head; tighten nuts by hand. 14. Slide muffler clamp on muffler inlet and install muffler on head pipe. Do not

tighten. Install mounting bolts into rear muffler support bracket. Do not tighten. Clamp header support tab to head pipe using CLAMP-002 and stock L shape bracket. Do not tighten. See Figure 5 & 6.

15. Starting at front of left head pipe, tighten all hardware while maintaining proper alignment of exhaust system. Reconnect O² sensor.

16. Install heat shields with CLAMP-001 loosely. Keep clamp screw head accessible.

17. Adjust heat shields while keeping them parallel and tighten. 18. Remove duct tape and any other protective items. Check transmission vent

hose to ensure that it does not come into contact with head pipe. 19. Reconnect battery; reinstall floorboards, seat, saddlebags, & side covers. 20. After Installation is done and before starting your motorcycle, clean your new

exhaust thoroughly with a soft cloth and a cleaning solvent that doesn’t leave any residue. Any oily residue, like fingerprints, will burn into the chrome. PAGE 2 OF 4

TOOLS REQUIRED

1. Flat blade screwdriver 2. 5/16" nut driver 3. 1/2", 9/16", 7/8” and 14mm combination wrenches 4. 1/4", 3/16" and 5/16" Allen wrenches 5. Snap ring pliers 6. Ft./Lb. torque wrench 7. 3/8" ratchet & extensions 8. 1/2" socket and 1/2", 9/16" & 5/8" deep well sockets

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REFERENCE PICTURES

FIGURE 1 FIGURE 2

FIGURE 3 FIGURE 4

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FIGURE 5

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PACKING LIST

2 - BOLT #10 1 - BRKT-002

1 - BRKT-003 7 - CLAMP-001

3 - 65283 1 - CLAMP-002

1 - PLUG 01 1 - WASHER #4

1 - ZIP STRIP 2 - WASHER #5

PAGE 4 OF 4 *NOTE* TUNING IS REQUIRED TO ENSURE PROPER PERFORMANCE OF THE ENGINE AND THE EXHAUST SYSTEM

PARTS LISTING