We were excited when we heard the R&D team at S&S Cycle whipped up a SuperStreet 2-into-1 full exhaust system for the Harley-Davidson Sportster. We just happened to have a 2020 Sportster 1200 in the shop in need of a power upgrade so we slapped some SuperStreets on to show you how and to give you a chance to hear the exhaust note. Even though we used a 2020 model the install’s basically the same for all Sportsters 2007-up. This is a 50-state compliant exhaust. With a high-flow air filter like an S&S Mini Teardrop, you can gain over 10 horsepower according to S&S Cycle's dyno results. Their stock bike made about 59 ponies and with the new exhaust, intake and a tune it pumped out a little over 70 horsepower.
How to Install S&S Cycle Super Street 2-into-1 Exhaust on a Harley Sportster
(But be sure to watch the video for more tips to make the job even easier and to hear these babies rumble!)
- First unplug the O2 sensors using a flat blade screwdriver
(Save the O2 sensors because you will be reusing them) - Take a ½” wrench or socket and remove mounting bolts underneath the stock mufflers
- Right above the rear master cylinder there’s a 9/16” Acorn nut that needs to be loosened in order to access the bolts on the headers
- Loosen flange nuts on exhaust ports. The flange nuts are ½” but you’re better off using a ¼” drive deep well because it’s easier to get it in the tight space
- Carefully remove stock pipes
- Remove mid-controls (5/16” Allen)
- Remove pulley cover (5/16” Allen)
- Take exhaust bracket off (5/16” Allen)
- Replace stock exhaust bracket with new S&S one. Don’t forget a dab of Loctite!
- Put pulley cover back on
- Remove O2 sensors (14mm) from old exhaust
- Use flat blade screwdriver to remove flanges off old exhaust
- Put 7/8” adaptors for O2 sensors into new exhaust (* For narrow band O2 sensor users only. Wide band sensors will plug right back in.)
- Screw O2 sensors back in
- Put flanges on new pipes
- Put heat shields on headers (hand tighten)
- Replace exhaust gaskets (S&S supplies new ones)
- Put new header back on. Start with rear, pull forward a little bit, then put front one on. Attach flange nuts (hand tighten)
- Slide torque clamp on new muffler with nut facing down
- Slide new muffler on
- Slide dogbone into slot under muffler and bolt into place
- Put on collector heat shield
- Tighten heat shields
- Tighten flange nuts
- Tighten torque clamp
- Tighten exhaust mount bolts
- Put foot control back on
- Put pin and e-clip back on brake shifter rod
- Plug O2 sensors back in
- Snap side panel back into place
- Before starting up bike, wipe new exhaust down well
