540R Laterals Rearset 2-Into-2 Exhaust for Harley-Davidson Sportster (1986–2022+)

540R Laterals Rearset 2-Into-2 Exhaust for Harley-Davidson Sportster (1986–2022+)

$750.00
The 540R Laterals Exhaust is a rearset-specific evolution of the original 540° Laterals, engineered for Sportster riders who demand maximum clearance, performance, and aggressive styling. Featuring a distinctive 180° front pipe and 360° rear pipe, this handcrafted 2-into-2 stainless system is built exclusively for mid-control and rearset Sportsters.
Kinetic Motorcycles

Exhaust Details

For O2 sensor sizing.

The end of the exhaust. If you chose 'No' on Custom Tips, then you are getting straight tips. .

Forwards, Mids, or Rearsets

USA Designed & Made
Worldwide Shipping
High Precision Motorcycle Parts
Product Information

The 540R Laterals Sportster Exhaust is purpose-built for performance-focused riders running rearsets or mid controls.

By reworking the routing of the original 540° Laterals, this version ensures proper leg, peg, and linkage clearance while preserving the iconic lateral pipe layout that defines the platform.

Each system is hand-TIG welded from mandrel-bent 304 stainless steel and internally ceramic-coated to reduce radiant heat and improve long-term durability.

Every exhaust undergoes multiple fitment checks during production to ensure consistent clearance and alignment across all compatible Sportster models (1986–2022+).

The 540R runs as an open 2-into-2 system for maximum flow and aggressive tone. Riders can further customize with segmented welds, tip styles, EFI O2 bungs, and an optional integrated stainless flange kit.

⚠ Not compatible with forward controls.

Specifications
Material
Mandrel-bent 304 stainless steel, hand-TIG welded
Coating
Internal ceramic coating
Diameter
1.75" at flange → stepped to full 2"
Configuration
2-Into-2 Laterals
Pipe Layout
180° front pipe / 360° rear pipe
Baffles
None (open performance system)
O2 Sensor Bungs
Optional (EFI 2007–2022+)
Flange Kit
Optional integrated stainless kit
Production Time
2–4 weeks (made to order)
Features
  • Rearset-specific routing for proper peg and linkage clearance
  • Signature 180° front / 360° rear lateral pipe design
  • Hand-TIG welded 304 stainless steel construction
  • Internally ceramic-coated tubing for heat reduction
  • Open 2-into-2 system for maximum flow and aggressive tone
  • Optional segmented pie-cut weld styling
  • Multiple exhaust tip options
  • Optional integrated flange kit for easier installation
Fitment
Iron 883
Nightster
Forty-Eight
Seventy-Two
Roadster
1200 Custom
Fitment Details:
  • Fits Harley-Davidson Sportster models (1986–2022+)
  • Compatible with rearset foot controls
  • Compatible with mid controls
  • Not compatible with forward controls
  • EFI bikes require O2 bungs unless using eliminators
Why Choose
Rearset-focused design for aggressive riding setups
Unique lateral routing creates standout visual impact
Open 2-into-2 layout delivers maximum exhaust flow
Internal ceramic coating improves heat control
Handcrafted TIG-welded stainless construction
Custom weld styles and tip options available
FAQs
Will this exhaust fit my Sportster?

Yes, if your bike has mid controls or rearsets. It will not work with forward controls.

What’s the difference between segmented and standard welds?

Segmented welds (pie cuts) give a raw race-inspired look. Standard welds are smooth and clean.

Do I need O2 bungs?

EFI Sportsters (2007–2022+) require O2 bungs unless using O2 eliminators.

How long is production time?

Typical turnaround is 2–4 weeks as each system is made to order.

Designed & Built in the USA

Every Kinetic product is designed and manufactured in the United States. Keeping our work in-house allows us to control quality, refine fitment, and stand behind every part we make.

A Decade of Hands-On Experience

Founded in 2013. A decade of machining, installing, riding and refining components on real bikes — not just in a lab. That experience shows in the quality of every part we ship.

Designed by Riders & Builders

Every product is shaped by hands-on building and riding experience, with practical decisions made where it matters most.

Innovation Meets Passion

Made in the USA

Founded in 2013 by Mike Le, Kinetic Motorcycles was built on a simple belief: motorcycle parts aren't generic hardware — they're personal. Every product begins as an original idea, designed by Mike and developed entirely in-house.

We don't rely on templates or outsourced shortcuts. Each part is shipped by hands-on fabrication experience and time spent riding, testing, and refining. Whether you're dialing in a daily rider or building something truly your own, our focus is the same — create parts that feel intentional, functional, and worthy of your motorcycle.

Innovation Meets Passion

What Our Customers Say

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