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Harley-Davidson V-Rod Destroyer Indy Series Exhaust REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 24-10-2010

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STOCK EXHAUST SYSTEM REMOVAL (DESTROYER) 1. Remove both collector bolts. 2. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 3. If the Racepak is installed, remove both O2 and EGT sensors from the front and rear head pipes. 4. Carefully remove complete exhaust from the motorcycle. STOCK EXHAUST SYSTEM REMOVAL (V-ROD) 5. Loosen clamp bolt at front of the collector using a 13mm socket. 6. Remove muffler bracket bolt using a 13mm wrench. 7. Carefully remove muffler and collector assembly from motorcycle. 8. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 9. Carefully remove head pipes from motorcycle. 10. Remove the stock exhaust flanges and circlips from both the front and rear head pipes. If the circlips are bent or twisted they should be replaced, Harley-Davidson part number #65045-01 We also recommend replacing the stock exhaust gaskets, Harley-Davidson part number #65109-01 INDY SERIES EXHAUST SYSTEM INSTALLATION 1. Identify front head pipe #7-8002. Install the stock flange and circlip. Install the exhaust gasket and front header pipe, leaving the flange nuts hand tight. 2. Repeat the above step for the rear head pipe #7-8006. 3. Slip the megaphone/collector assembly onto the head pipes, secure with the four springs supplied using the spring puller tool. 4. Rotate the exhaust so there is adequate clearance in all places. 5. Tighten the cylinder head flange nuts for both the front and rear head pipes. 6. Tighten both the EGT and O2 plugs on the front and rear head pipes. 7. Clean all fingerprints from the exhaust using a contact cleaner (or other non flammable cleaner). Fingerprints will leave stains on the pipe once the motorcycle is started. 8. You are now ready to start the motorcycle.

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HARLEY DAVIDSON SOFTAIL SPRINGER Dual Slip-On Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK MUFFLERS 1. Loosen the bolt on the pinch clamp at the front end of each muffler. 2. Remove the two bolts that mount the muffler to the mounting bar. Repeat this step on the opposite muffler. 3. Remove the stock mufflers and set them aside. Note: It may be necessary to use a penetrating lubricant to loosen the mufflers from the head pipes. INSTALLING YOUR NEW VANCE & HINES SLIP-ON EXHAUST SYSTEM 1. Remove the two 5/16″ flanged head bolts from the bracket that is welded to the backside of each muffler. Attach one of the mounting brackets (supplied) to each muffler, using two of the 5/16″ flanged head bolts (removed earlier), leaving them loose at this time. When the bracket is mounted correctly on the muffler, the single hole end should point down when the muffler is mounted to the bike. 2. Be sure there is a muffler clamp (supplied) over the front (notched end) of each muffler. 3. Slip the muffler onto the stock head pipe, mount the muffler to the rear most hole of the stock mounting bar, using one of the stock bolts and tighten. Repeat this step on the opposite muffler. Note: When installed correctly, the Vance & Hines logo on the muffler should face outwards. 4. Tighten the two muffler clamps. 5. Tighten the two 5/16″ flange bolts on each muffler bracket. 6. Wipe any finger prints or oil off any chrome parts of the exhaust system before starting the motorcycle. 7. Be sure to tighten all hardware before starting your motorcycle. RE-JETTING INSTRUCTIONS Re-jetting the carburetor will result in realizing the “full” potential of this performance exhaust system. Vance & Hines offers jet kits for most applications

HARLEY DAVIDSON Softail Big Shots Staggered Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. If equipped, loosen the floor boards to gain clearance for exhaust removal and installation. 2. Loosen heat shield clamps on both the front and rear head pipes. 3. If equipped, loosen crossover pipe clamp, located between front and rear head pipes. 4. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach mufflers to the frame. 6. Remove the complete exhaust system and set aside. Assistance may be required. 7. Remove stock mounting bars and brackets. 8. On models equipped with upper mounting bar attached at swing arm pivot bolt, go to step 9. If upper mounting bar is attached with two torx bolts (not swing arm bolt) go to step 10. 9. Remove right side 1/4″-20 bolt which holds lower fender in place. The fender will flex outwards allowing removal of right passenger foot peg bolt. Park the motorcycle on its side stand. Position a floor jack under right hand frame tube of the motorcycle below swing arm pivot bolt. Raise jack just enough to take the weight off swing arm pivot bolt. Remove swing arm pivot bolt and stock upper mounting bar. Replace swing arm pivot bolt and torque to 120 ft. lbs. Reinstall passenger foot peg using 1/2″-20 x 3″ bolt and 1 5/8″ long spacer (supplied). Reinstall 1/4″-20 fender bolt. 10. Using a T50 torx driver, remove the three mounting bolts and mounting bar. (Two of the bolts are visible, the third also attaches right hand passenger foot peg pivot and is accessed by removing foot peg. Reinstall foot peg using 3/8″x 2-1/2″ Allen bolt and 3/4″ long spacer (supplied). 11. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. (Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A)

HARLEY DAVIDSON SOFTAIL 2 into 1 Pro Pipe Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Loosen the crossover pipe clamp, located between the front and rear head pipes. 3. Remove the two mounting nuts from each head pipe, located at the cylinder head. 4. Remove the two nuts from the back side of each muffler. 5. Remove the entire exhaust system and set it aside. 6. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them. 7. Remove the two bolts that hold the front muffler mounting bar to the frame. Note: FLSTN, FLSTF models require the removal of the stock exhaust system mounting bar. For removal: Remove the right passenger foot peg bolt. Position the motorcycle on it’s side stand with a floor jack under the swing arm pivot bolt on the right hand side. Raise the jack just enough to take the weight off the pivot bolt and remove the bolt and stock mounting bar. Replace the pivot bolt and torque it between 120 -150 ft. lbs. 8. Reinstall the foot peg bolt using the 1/2″ x 3″ bolt and spacer tube (both supplied). Tighten the bolt making sure the foot peg folds in the proper direction. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM Note: For easier installation on models with floorboards, it will be necessary to loosen the right side floorboard. 1. Check the stock exhaust gaskets to be sure they’re in good shape. If you have any doubts as to their condition, replace them. 2. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of each heat shield. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the motorcycle. 3. Install the circlips and flanges from the stock system onto both new head pipes. 4. Install the header using the stock nuts, but leave them loose at this time. 5. Install the new mounting bracket to the frame below the right rear foot peg, using the two 3/8″x 3/4″ flange bolts (supplied), and tighten. 6. Slide the dog bone shaped nut plate under the bracket that is welded to the backside of the muffler.

HARLEY DAVIDSON SOFTAIL Shortshot Exhaust System REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 17-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. On FLSTC, FLSTF, FLSTN and FXSTS loosen the right hand floor board mounting bolts to gain clearance for exhaust removal and installation. 2. Loosen the heatshield clamps on both front and rear exhaust pipes. 3. Loosen the crossover pipe clamp, located between the front and rear head pipe. (This step is not necessary on 2000 models). 4. Remove the two mounting nuts from each head pipe, located at the cylinder head. 5. Remove the bolts that attach the mufflers to the frame. 6. Remove the entire exhaust system and set it aside. 7. On pre 2000 models remove the lower mounting bar. 8. FLSTN, FLSTF and FXSTD models have an upper mounting bar that must be removed in addition to the lower bar. 9. Park the motorcycle on its side stand. Remove the right side 1/4″-20 bolt which holds the lower fender in place. The fender will flex out of the way allowing the removal of the right passenger foot peg bolt. Position a floor jack under the right hand frame tube of the motorcycle below the swing arm pivot bolt. Raise the jack just enough to take the weight off the pivot bolt and remove the bolt and stock mounting bar. Set the mounting bar aside. Replace the pivot bolt and torque it between 120 -150 ft. lbs. Reinstall the passenger foot peg using the 1/2″-20 x 3″ bolt and an 1 5/8″ long spacer (supplied). 10. On 2000 year models, using a #50 Torx driver, remove the three mounting bolts, and set the mounting bar aside. (Two of the bolts are visible, the third is accessed by removing the right hand passenger foot peg.) Replace the foot peg using the 3/8″-16 x 2 1/2″ bolt and 3/4″ length spacer (supplied). 11. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. NOTE: If circlips look bent or twisted replace them with new circlips. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Vance and Hines recommends you replace your exhaust gaskets with Sceamin’ Eagle gaskets part number 17048-98. 2. Install the mounting bracket to the frame, by aligning the two 3/8″ holes in the bracket with the two holes in the frame below the right rear footrest, using the two 3/8″-16 x 3/4″ flange head bolts (supplied), do not tighten at this time. When the bracket is mounting correctly, it should bend out and away from the motorcycle, with the four holes of the bracket toward the front of the motorcycle. 3. Install the circlips and flanges from the stock system on to both of the new head pipes

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HARLEY-DAVIDSON SOFTAIL CROSSOVER REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-04-2012

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EXHAUST SYSTEM REMOVAL READ ALL INSTRUCTIONS BEFORE BEGINNING 1. Under the oil tank on the right hand side, locate the rear O² sensor connector. Unplug sensor and feed the end of wire through the frame freeing it from motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Open the plastic cover above the rectifier on front of the frame to access to the front O² sensor connector. Unplug sensor from harness. Remove ZIPSTRIP holding wire to frame and feed the wire through freeing it from motorcycle. 3. On floorboard equipped models, loosen the right hand floorboard mounting bolts to gain clearance for exhaust removal and installation. 4. Loosen the heat shield clamps on both front and rear exhaust pipes. 5. Remove the mounting nuts from each head pipe, located at the cylinder head. 6. Remove the nuts attaching the exhaust mount bracket to the frame. 7. On FLSTD and FLSTF models, you will need to remove the right side passenger foot peg and hanger, as this is attached to the exhaust mount bracket. Replace the passenger foot peg assembly using the BOLT 14 Allen bolt (supplied). 8. Remove the entire exhaust system and set it aside. 9. Remove the two lower mounting studs from the frame See figure 1 . Recommended replacement exhaust port gaskets, H-D P/N: 65324-83A. 10. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. See figure 2 . NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. 11. Remove O² sensors from stock head pipe and set aside for re-installation on your new RUSH exhaust system. PAGE 1 OF 4 RUSH RACING PRODUCTS EXHAUST SYSTEM INSTALLATION P/N 7020 – 7120 BEFORE INSTALLATION PLEASE READ ALL INSTRUCTIONS 1. Remove header and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark outside edge of each heat shield to show location of mounting clips that hose clamps will loop through See figure 3. 2. Apply a small amount of anti-seize compound to the threads of the O² sensors and install them into the new head pipe. NOTE: Be careful not to get anti-seize on sensor tip, it may affect sensor function. 3. Install circlips and flanges from stock system onto the new head pipe See Figure 2. Note: Replace circlips if bent or damaged 4. Attach BRKT-007 to frame using two BOLT 12 Tighten to factory specs. 5. Install complete assembly into exhaust ports (rear port first). Use stock flange nuts, Do Not Tighten .

Harley Davidson Softail Sideshots Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 20-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. On FLSTN, FLSTF, FLSTH and FLSTC loosen the right hand floor board mounting bolts to gain clearance for exhaust removal and installation. 2. Loosen the heat shield clamps on both front and rear exhaust pipes. 3. Loosen the crossover pipe clamp, located between the front and rear head pipe. (Not necessary on 2000- up models). 4. Remove the two mounting nuts from each head pipe, located at the cylinder head 5. Remove the bolts attaching the mufflers to the frame. 6. Remove the entire exhaust system and set it aside. 7. On pre 2000 models remove the lower mounting bar. 8. FLSTN, FLSTF and FXSTD models have an upper mounting bar that must be removed in addition to the lower bar. On pre 2000 models go to step #9, on 2000-up models go to step #10. 9. Remove the right passenger foot peg bolt. Position the motorcycle on the side stand with a floor jack under the swing arm pivot bolt on the right hand side. Raise the jack just enough to take the weight off the pivot bolt, remove the bolt and stock mounting bar. Reinstall the pivot bolt and torque to 120 -150 ft. lbs. Reinstall the passenger foot peg using the 1/2″ x 3″ Allen bolt and 1-5/8″ length spacer (supplied). 10. Using a #50 Torx driver, remove the three mounting bolts, and set the mounting bar aside. (Two of the bolts are visible, the third is accessed by removing the right hand passenger foot peg.) Replace the foot peg using the 3/8″ x 2 1/2″ Allen bolt and 3/4″ length spacer (supplied). 11. The bolts and spacers used in the above steps may also be used on all Softail models to space the right rear foot peg away from the exhaust. 12. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers (save for reuse). NOTE: If circlips look bent or twisted replace them with new circlips.

Harley davidson American Classic Straights on a 1988-2001 VLX 600 Shadow Installation Instructions

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Filed Under (Harley Davidson) by admin on 01-03-2012

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Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove bolts that are holding pipes at rear mounting bracket. 3. Loosen clamps at mufflers. 4. Remove mufflers. 5. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 6. Remove rear exhaust pipe assembly. 7. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 8. Remove front exhaust pipe assembly. 9. Remove exhaust-mounting bracket from frame. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system.
1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. (See Illustration) 3. Install Front exhaust header pipe, taking care to not scratch chrome surfaces on pipe, engine or motorcycle — use masking tape as needed. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install nut strip into slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the rear cylinder head — DO NOT TIGHTEN NUTS! 8. Install nut strip into slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration. 15. Before starting bike wipe off any fingerprints and grease off pipes. Start bike and check for any exhaust leaks.

2008 Harley Davidson Softail Deluxe Exhaust Installation Supplement to Installation Manua

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Filed Under (Harley Davidson) by admin on 16-02-2011

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1. Install LH and RH passenger foot peg mount using 3/8×2-1/4″ hex head bolts, 3/8″ SAE flat washers, 3/8″ lock was and 1″ spacers between the motorcycl frame and mount. Figure 1 hers e xhaust ter) n’t Cut 6-1/4″ from end Cut 1/2″ from end Figure 2 2. Remove exhaust chrome covers from header pipes. 3. It is not necessary to remove the front cylinder’s front cover. Remove header pipes from cylinder heads. Cut pipes as shown in Figure 2. 4. Replace header pipes Cut cover 5-5/8″ from end – Shown already cut Figure 3 5. Cut top cover as shown in Figure 3. 6. Install supplied extension pipes as shown in Figure 3 using the OE e clamps. (Clamps covered by covers in picture – covers will be installed la Rotate clamps to make sure they don’t interfere with the foot peg mounts. Do tighten clamps yet. 7. Mount exhaust hanger bracket to body frame with (3) supplied vibration mounts. Figure 4. Figure 4 8. Install supplied clamps to ends of mufflers and fit over exhaust extensions. 9. Attach exhaust pipes to hanger bracket with OEM hardware (4 bolts). Apply Red Loctite to OEM bolts. Figure 4. 10. Install all chrome covers 11. Tighten all exhaust clamps. Figure 5 12. Install supplied chrome cover with clamp removed from cut OE chrome cover. Supplied cover slips over OE chrome cover. Push cover forward to prevent the body from hitting the cover. Figure 5. 13. Move OE clamp backwards and install 14. Position luggage rack as shown in figure 5. Install luggage rack with OE bolt in the Figure 6 Bracket OE Bolt Clamp Figure 7 Drill ¼” holes bracket using OE bolt and supplied 3/8″ bolt. Figure 6. 7 and drill two ¼” holes in shock tower mount. 1 rear and the supplied ¼” bolts in the front.

HARLEY-DAVIDSON SOFTAIL STRAIGHTSHOTS 2-2 INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2012

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1. Under the oil tank on the right hand side, locate the rear O2 sensor connector. Unplug sensor and feed the end of wire through the frame freeing it from motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Open the plastic cover above the rectifi er on front of the frame to gain access to the front O2 sensor connector. Unplug sensor from harness. Remove cable tie holding wire to frame and feed the end of the wire through, freeing it from motorcycle. 3. On FLSTC, FLSTF, FLSTN and FLSTSC models, loosen the right hand fl oor board mounting bolts to gain clearance for exhaust removal and installation. 4. Loosen the heat shield clamps on both front and rear exhaust pipes. 5. Remove the two mounting nuts from each head pipe, located at the cylinder head. 6. Remove the nuts attaching the exhaust mount bracket to the frame. 7. On FLSTN, FLSTF and FXSTD models, you will need to remove the right side passenger footpeg and hanger, as this is attached to the exhaust mount bracket. Remove hanger, and replace the passenger foot peg assembly using the 3/8″ x 2 1/2″ Allen bolt (supplied). 8. If equipped, unbolt the carriage bolt and clamp attached to the bracket under the right side transmission cover. 9. Remove the entire exhaust system and set it aside. 10. If equipped, remove the bracket from under the right side transmission cover. 11. Using a 7/8″ or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 12. Remove the two lower mounting studs from the frame (Figure 1). 13. Carefully remove exhaust port fl anges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition. Recommended replacement exhaust port gaskets, Harley part number:17048-98 or 65324-83A

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