Pipe Dreamz, Sportster Exhaust Installation Instructions For 2004-2006!!

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Installation Instructions for Harley Davidson Sportster Year Models 2004 – 2006

1. If you still have the stock 2004 – 2006 air cleaner on your Sportster®, you must trim the black plastic air scoop under the cover or it will hit the new pipes. You could also replace the cover with a Screaming Eagle® style , Kuryaken, or even a stock 1991-2003 air cleaner. These can be found used for $15 to $25 at swap-meets or aftermarket motorcycle shops. Also, at this time it is helpful to cover the starter motor (under the rear-cylinder,) with a rag or a piece of cardboard just in case you drop a nut. They can be very difficult to retrieve if they fall under the starter motor. Be sure the motor is cold.
2. Remove the old, stock foot peg mount from the frame.
3. Remove the folding foot peg from the stock foot peg mount.
4. Install the new, offset foot peg mount to the frame using the two long bolts and two spacers. From this point on apply blue locktight to all the bolt threads when you install them.
5. Remove the factory pipes from the exhaust heads and the rear mounts. You must also remove the brake-rod, due to the fact it passes through the pipe mount. Use a good Allen wrench as Harley Davidson® uses threadlock, making the bolts difficult to remove.
6. Remove C-clips and flanges from the stock pipes. It is not always necessary, but recommended, to have a set of Screaming Eagle® style gaskets and extra C-clips on hand. (The Screaming Eagle® style gaskets can be helpful as back-ups and because they are thinner, allowing the pipes to seat themselves deeper in the exhaust heads. To remove the C-clip, with a set of vise-grip pliers, grip the clip about 1.5 inches from either end, and lift up and away. Be careful not to stretch the clip or it will not fit flush into the flanges when installing.
7. Place the flange you wish to use on the new pipe, with the groove facing the exhaust head.
8. Re-install the C-clips over the pipe being careful to pull up and over, do not stretch to the side. If you find it difficult, having a friend help can make this part of the process more comfortable.
9. Install torque cones into exhaust heads, see instructional photo.
10. On most models the exhaust gaskets must be replaced with the thinner Harley Davidson® Screaming Eagle® style gaskets to allow the pipes to enter the heads deeper.
11. Bolt the front pipe, loosely, to the exhaust head. Make sure to leave a loose fit.
12. Bolt the rear pipe up, and leave a loose fit.
13. Bolt the mount to the side of the transmission cover, see diagram.
14. Loosely attach the two pipes together through the slot in the chrome mount.
15. Tighten all bolts, making sure to check Harley Davidson® reference guides for proper torque on your model year bike.
16. DO NOT OVERTIGHTEN! Stripped or broken head-studs are very expensive to replace.
17. Remember, Pipe Dreamz sells straight pipes, which may not meet your state E.P.A. or noise requirements. Also, Harley Davidson® may not warranty your bike if it has aftermarket parts installed. Make sure to save all your original parts in the event you have a major mechanical problem.
18. Be sure to read the enclosed blueing information for instructions on breaking in your new Pipe Dreamz pipes!
19. IMPORTANT: After your new pipes are installed, be sure to start your bike, let it run for a minute, shut it off and repeat this process (3) three more times. This allows the heat to be distributed into the pipes evenly.

Torque Cones, install a set of HEADER PIPE CONES into your headpipes! To increase lo-end torque and to create the correct amount of back pressure! A must for straight pipes! Simple to install between head and pipe.

Torque-Cones (Pair) $30.00
New Screaming Eagle style thinner gaskets $10.00

People think straight pipes make more horsepower. WRONG!

They are under the false impression that if the engine breathes better and gets rid of the unwanted exhaust fumes faster, they will go faster . . . Credit goes to Jerry Branch, the genius of Flowmetrics to understand how back pressure is needed to scavenge the unburned portion of fuel back into the combustion chamber to create more horsepower.

IT REALLY WORKS!

PROBLEM: Harley riders & custom exhaust pipe manufacturers, want the clean, cool looks and hot sound of straight pipes.

SOLUTION: Torque cones, (power cones, torque valves) a small 2” funnel style venturi valve that provides the correct back pressure by creating a tube constricted in the middle and flared on the end. This operates on the principle that the exhaust velocity will increase and it’s back pressure decreases when passing through the torque valve. At low speeds, the taper in the valve increases back pressure resulting in increased low RPM power and torque. At high speeds, the venturi effect created by the torque valve increases exhaust gas velocity. This maximizes engine power by increasing the rate at which the exhaust gases are drawn from the exhaust ports.

We strongly recommend torque cones be used with any straight pipe.

<< Martin Brothers Drag Pipes >>   <<More Harley Davidson Exhaust>>  << Harley Davidson Drag Pipes >>   << Samson Exhaust >>

 << More Harley Exhaust >>  << 86-03 Sportster Drag Pipes >>   << 2004 Sportster Drag Pipes >>   <<Pipe Dreamz Sportster  Exhaust>>

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