KessTech ESM2 User manual
INSTALLATION MANUAL
Harley-Davidson Softail Slipons
ESM2 ESM3
Feel the Sound.
01. Remove the seat. Dismount OEM slipon without tension (if necessary the manifold as well). If
provided, put the catalyst into the manifold. Mount the KT slipons. Line up the whole system
without tension. The slipons should be in parallel position. Tighten the slipon-clamps to a torque
of 39-41 nm and tighten the headers again.
HD SOFTAIL SLIPONS ESM2 ESM3 01a
HD SOFTAIL SLIPONS ESM2 ESM3 02
HD SOFTAIL SLIPONS ESM2 ESM3 03
Example of soldering
02. Mount handlebar switch with the help of the supplied screw. Install the cable starting at the
handlebar switch and position it under the tank towards the KT electronics.
03. Solder the KessTech electronics into the existing electronics. Use cable colors and pin
according to the wiring diagram KessTech electronics. Connect all wiring plugs. Line up the
complete KessTech electronics. Do not place it directly at highly heated bodies. Install all cables
de-energized and secure them with cable clamps (cable ties) so that they cannot be crushed
or rest at the manifold or the exhaust.
HD SOFTAIL SLIPONS ESM2 ESM3 01b
04. Wiring diagram for KT electronics with the cable colors of the Harley-Davidson models.
Yellow cable – RPM signal, green cable – speed signal
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
05. Safety Note:
After about 200 kms retighten all exhaust screws and after every service intervals as well as
every 4,000 kms. If not correctly performed, the KessTech warranty will be void. If there is any
subsequent change of the exhaust, the vehicle type-approval will be invalid.
06. Modelspecicfeatures:
A. Footrest for complete line Breakout.
Screw screws 3/8 UNCx1“ in the OEM hole (picture taken with snap ring and washer) about
5mm from behind. Insert the footrest transfer plate and securely tighten the screw. Mount
footrest with 3/8“x2,5’’ screws onto the footrest transfer plate and counter from behind with
3/8’’ UNC nuts (included in scope of supply).
HD SOFTAIL SLIPONS ESM2 ESM3 06a
B. Speed sensor and sensor holder for Softail Evolution models up to 1996. Mount the speed
sensor swingarm on the left side of the rear tire. Install the supplied holder bracket using the
rear screw of the cover mount (see picture). Mount sensor using the lock nuts on the bracket
sothatthedistancetoallvescrewheadsofthepulleyis4mm(+/-10%).
C. Catalyst for Softail models from 2007. Plug the catalyst (L = 66 mm) into the upper manifold
with the side, that is turned off. Plug the catalyst (L = 90 mm) into the lower manifold with the
side, that is turned off. To compensate for production tolerances, it is recommended to weld the
catalyst on the manifold. For TC 103 models two catalysts (L = 90 mm) are included.
HD SOFTAIL SLIPONS ESM2 ESM3 06f
HD SOFTAIL SLIPONS ESM2 ESM3 06b HD SOFTAIL SLIPONS ESM2 ESM3 06c
HD SOFTAIL SLIPONS ESM2 ESM3 06d HD SOFTAIL SLIPONS ESM2 ESM3 06e
66mm
Leathed side into manifold/header
KESSTECH GmbH
Sailershäuser Straße 1
D-97531 Obertheres
Phone: +49(9521)95420-0
Fax: +49(9521)95420-122
Mail: [email protected]
www.kesstech.de/en
Installation manual Harley-Davidson Softail Slipons ESM2 ESM3
Version: 07/2018
Amendments and errors reserved.
07. Other information:
The following additional support letters can be found in the “Technical Help“ section in the
Dealer-Login of our website www.kesstech.de/en:
• Jumper plug to avoid the error message on the display
• Jumper plug MUM-5 shortcut 2
• Jumper plug MUM-5 aoo
• Shell mounting
• Description ESM2 function
• Care instructions Black Velvet
KessTech exhaust systems are always developed, constructed, designed and homologated to
the delivery condition of the original vehicle. KessTech cannot evaluate whether the installation
of further accessory parts together with a KessTech exhaust system is possible and still legal
and therefore assumes no warranty or liability. Our Technical Support will be happy to answer
any question.
For warranty claims, see the section “Warranty Processing“ in the Dealer-Login of our website
www.kesstech.de/en, as well as the general terms and conditions.
If you need more information or have any further questions, feel free to contact us.
Your KessTech Team
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