KessTech ESM2 - User Manual

INSTALLATION MANUAL
Harley-Davidson Softail Slipons
ESM2 ESM3
Feel the Sound.

Summary

01. Installation Procedure

Remove and Mount Slipons

Remove OEM slipons, mount KT slipons, align, and tighten headers and clamps.

Install Handlebar Switch

Mount handlebar switch and route cable towards KT electronics under the tank.

Solder KessTech Electronics

Solder KessTech electronics using wiring diagram, connect plugs, and secure cables away from heat.

04. Wiring Diagram

Wiring Specifications by Model

Wiring diagram for KT electronics with cable colors for various Harley-Davidson models and years.

05. Safety Note

Periodic Maintenance and Warranty

Retighten exhaust screws periodically; failure voids warranty. Vehicle type-approval invalidation.

06. Model Specific Features

Footrest for Breakout Models

Specific instructions for mounting footrests on Breakout models using transfer plates and UNC screws.

Speed Sensor for Evolution Models

Mount speed sensor and holder for Softail Evolution models up to 1996 with specific pulley clearance.

Catalyst Installation for Softail Models

Instructions for installing catalysts (66mm/90mm) into manifolds for Softail models from 2007.

07. Other Information

Additional Support and Contact Details

Links to additional support letters, description of ESM2 function, and contact information for KessTech.

Overview

1. Function Description
2. Important Technical Specifications
3. Wiring Diagram for KT Electronics (Harley-Davidson Models)
4. Usage Features
5. Maintenance Features

This document is an installation manual for KessTech Harley-Davidson Softail Slip-on exhaust systems, specifically models ESM2 and ESM3. It provides detailed instructions for installation, wiring, and model-specific features, along with important safety and warranty information.

Function Description:

The KessTech Softail Slip-on exhaust systems are designed to replace the original equipment manufacturer (OEM) slip-ons on Harley-Davidson Softail motorcycles. These systems are developed, constructed, designed, and homologated to integrate with the original vehicle's condition. They are intended to enhance the sound and performance of the motorcycle, offering a customizable riding experience with features like adjustable sound (ESM2/ESM3). The manual emphasizes that the installation of further accessory parts with a KessTech exhaust system may affect legality and warranty, and KessTech does not assume liability for such modifications.

Important Technical Specifications:

• Torque Specifications: Slip-on clamps should be tightened to a torque of 39-41 Nm.
• Catalyst Dimensions: For Softail models from 2007 onwards, catalysts are included. The upper manifold catalyst has a length (L) of 66 mm, and the lower manifold catalyst has a length (L) of 90 mm. For TC 103 models, two 90 mm catalysts are included.
• Speed Sensor Distance: For Softail Evolution models up to 1996, the speed sensor should be mounted with a distance of 4 mm (+/- 10%) to all five screw heads of the pulley.
• Footrest Screws (Breakout models):
  • Screws for OEM hole: 3/8 UNC x 1 inch.
  • Screws for footrest transfer plate: 3/8 inch x 2.5 inches.
  • Nuts for footrest transfer plate: 3/8 inch UNC.

Wiring Diagram for KT Electronics (Harley-Davidson Models):

The manual provides a comprehensive wiring diagram for various Harley-Davidson Softail models, detailing the connection points for the yellow cable (RPM signal) and green cable (speed signal), along with ignition plus connections.

Model	Year	PIN/YELLOW CABLE	PIN/GREEN CABLE	INFORMATION	IGNITION PLUS
EVO Softail	1984-1995	dark green / white	external speed sensor		orange / white
EVO Softail	1996-1999	pink	white
TC88 Softail	1999-2003	29 blue / orange	white	carburetor	orange / white
TC88 Softail	2003-2007	29 blue / orange	33 white / green	only injector	orange / white
TC96 Softail	2007-2010	29 blue / orange	33 white / green		orange / white
TC96 Softail	2011	29 green / blue	33 light green/yellow		orange / white
TC103 Softail	2012-	2 green / blue	4 light green/yellow	black connector	orange / white
TC110 Softail	2007-2010	29 blue / orange	33 white / green		orange / white
TC110 Softail	2011	29 green / blue	33 light green/yellow		orange / white
TC110 Softail	2012-	2 green / blue	4 light green/yellow	black connector	orange / white

Usage Features:

• Handlebar Switch: The system includes a handlebar switch for controlling the exhaust. This switch is installed with a supplied screw, and its cable is routed under the tank to the KessTech electronics.
• Electronic Integration: The KessTech electronics are soldered into the existing motorcycle electronics. Cable colors and pin assignments must follow the provided wiring diagram.
• Cable Management: All cables should be installed de-energized and secured with cable clamps (cable ties) to prevent crushing or resting on hot components like the manifold or exhaust. The KessTech electronics should not be placed directly on highly heated bodies.
• Model-Specific Adaptations:
  • Footrest for Breakout Models: Specific instructions are provided for installing a footrest transfer plate and mounting the footrest using supplied screws and nuts.
  • Speed Sensor for Softail Evolution (up to 1996): Instructions detail mounting the speed sensor swingarm on the left side of the rear tire, installing a holder bracket, and positioning the sensor to maintain a specific distance from the pulley screw heads.
  • Catalyst Installation for Softail (from 2007): Catalysts are inserted into the upper and lower manifolds. Welding the catalyst to the manifold is recommended to compensate for production tolerances.

Maintenance Features:

• Retightening Screws: A crucial safety note advises retightening all exhaust screws after approximately 200 km of use, and subsequently after every service interval, as well as every 4,000 km. Failure to do so can void the KessTech warranty.
• Vehicle Type-Approval: Any subsequent change to the exhaust system will invalidate the vehicle type-approval.
• Warranty Information: Warranty claims are processed according to the "Warranty Processing" section in the Dealer-Login on the KessTech website (www.kesstech.de/en), which also contains general terms and conditions.
• Additional Support: The "Technical Help" section in the Dealer-Login provides further support documents, including:
  • Jumper plug to avoid error messages on the display.
  • Jumper plug MUM-5 shortcut 2.
  • Jumper plug MUM-5 aoo.
  • Shell mounting.
  • Description of ESM2 function.
  • Care instructions for Black Velvet.

The manual emphasizes that KessTech exhaust systems are designed for the original vehicle condition, and the company cannot evaluate or guarantee the legality or compatibility of installations involving other accessory parts. For any questions or further information, customers are encouraged to contact the KessTech team.

KessTech ESM2 Specifications

General

Brand	KessTech
Model	ESM2
Category	Motorcycle Accessories
Language	English