In this how-to tutorial, Todd gives an easy step by step process on installing Lowbrow Customs 2 into 1 SuperMeg by Kerker for Sportsters onto a 2006 Harley-Davidson Sportster.
Lowbrow Customs has teamed up with Kerker to bring you an affordable, USA-made, high-performance, 2 into 1 exhaust system for your 2004-2013 Harley-Davidson Sportster. Our goal was to create an exhaust system we would want to run on our bikes, stripped of all the superfluous covers and branding. We continuously find ourselves drawn to performance race vehicles. Form follows function, and this exhaust system is all business. Available in everyone's favorite color, black, this expertly crafted exhaust is also available for Harley-Davidson Dyna and Softail model motorcycles.
5/16 socket with 1/4 nut driver
External lock ring pliers
Short socket extension
Long socket extension
3/16 allen socket
2 - 1/2 wrenches
3/8 drive ratchet
1/4 drive ratchet
Remove stock exhaust pipes from cylinder heads
Step 1: Remove your stock or other exhaust system from your bike.
- Remove heat shields using 1/4 drive 5/16 socket on your nut driver which we find easier than a flat head, but if thats all you have get at it.
- Unplug your 02 sensors if you have them.
- Remove nuts from exhaust flanges located on the cylinder heads with 3/8 drive 1/2 inch socket (front & rear). We suggest to spray some penetrating oil or WD40 on each of the studs and let them sit for a few minutes before trying to remove them. The last thing you want to do is break off a stud in your cylinder head.
- Remove bolts attaching the mufflers to the support bracket.
- You now can carefully remove the entire exhaust system.
- Remove the O2 sensors if you have them
- Remove the right side pulley cover to gain access to the mounting bracket.
- Remove the mounting bracket.
Remove right side pulley cover and stock exhaust mounting bracket.
Step 2: Remove retaining rings & flanges from the stock exhaust using external lock ring pliers. If the rings are extremely corroded or warped, we suggest to use a new set. Install the rings and flanges on to the new exhaust. *Note: Make sure the flange goes on first before ring and with the lipped indention facing out. You can use a piece of tape on the flanges to keep them from sliding up and down the pipe and scratching up the black finish.
Remove retaining rings and flanges from stock pipes using external lock ring pliers.
Install flange with indention facing out and use a piece of tape to keep the flange from sliding down and ruining your new black finish.
Install the retaining rings making sure they seat into the indentation of the flange.
Step 3: Install the O2 sensors into the new pipes and or O2 sensor plugs that come with the hardware kit, depending on your set up. Included is some anti-seize that you can put on the threads of the O2 sensors but be sure not to get any on the actual sensor or you may run into some issues.
Note* These pipes have threaded bungs designed for 18MM sensors, if your bike has 12MM you will need to purchase some 02 port bushing adapters.
Install O2 sensors and or sensor plugs onto the new header pipes.
Step 4: Using the correct fasteners from the supplied hardware kit, install the mounting bracket to the two holes located near the front pulley. Depending on your set up you may have to move your brake arm to tighten the bottom bolt. This 2006 Harley-Davidson Sportster has forward controls so we had to remove the bolts holding the bracket of the peg to lower the brake arm out of the way. When tightening down the bracket make sure the small hole on the bottom left is lined up.
Installing mounting bracket to the two right bolt holes under the pulley gear.
Make sure to line up the left small hole so the right side cover can be re-installed easily.
Step 5: Re-install the right side cover.
Tighten all three bolts of the right side cover.
Step 6: Check your exhaust gaskets and replace if necessary.
Step 7: Loosely install the 2 into 1 header pipe onto the cylinder heads.
When installing pipes to the cylinder heads make sure to get the flanges over the studs. It may help moving the pipe from front to back, it can be a tight fit.
Loosely tighten each bolt on the cylinder heads leaving wiggle room to allow for the muffler to be installed onto the header.
Step 8: Slide the clamp over the muffler and install the muffler on to the header pipe lining up the channel of the muffler to the mounting bracket. Pulling the muffler channel away from the bracket, insert the T-bolts and align with the holes on the bracket.
Slide the muffler onto the headers. This step can be difficult sometimes, take your time and work the muffler up & down and back & forth to open up the part of the muffler that fits onto the headers, lining the muffler channel to the mounting bracket.
Step 9: Tighten down the muffler to the mounting bracket using 1/2 wrench. Tighten down the muffler clamp using a 3/16 allen socket.
Using the hardware in the kit secure the T-bolts to the exhaust mount.
Tighten the muffler clamp down, don't over do it or you could break the clamp.
Step 10: Once the muffler is secure onto the 2 into 1 pipe and the exhaust mounting bracket, tighten down the 4 nuts on the cylinder head. Tighten these evenly and do not over do them again the last thing you want is to break a stud off on your cylinder head.
Tighten down the 4 nuts on the cylinder head evenly.
Step 11: Plug in your O2 sensors if you have them. Tune your bike accordingly and go for a ride!
If you have a 2007 and up model and are in need of a tuner check out Dyno Jet Power Commander 5 for your year range Sportster.
The End Result
How-to video coming soon. In the mean time, you can learn more on how to DIY install shotgun exhaust pipe to 2004 & up Harley Sportster with our graphic tutorial