Assembly & Installation Instructions for Model Years 2004 – 2007
(Printable View)

1. If you still have the stock 2004 – 2007 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 fIf you still have the stock 2004 – 2007 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. lding 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, pull out the old thick gasket from inside the cylinder heads, they may be difficult to see, but use a knife to pry them out. The exhaust gaskets must be replaced with the thinner Harley Davidson ® Screaming Eagle ® style gaskets to allow the pipes to enter the heads deeper. To remove the C-clip, use 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. Remember . . . 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. Be sure to wipe any fingerprints, grease, or oil stains from your new pipes with acetone, before starting! Dirt or oil stains will burn permanently into the chrome.
20. WARNING! . . . HOT exhaust pipes can cause serious burns! Use caution!
21. Pipe Dreamz recommends your new pipes be installed by a professional.