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YAMAHA V-STAR 1300 exhaust system INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 08-11-2010

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1. Install the bracket (Stamped 439-P, supplied) to the motorcycle chassis using the 10 x 20mm hex head bolt (supplied) and two of the stock mount bolts in the bottom holes (Figure 3). 2. Remove exhaust system and heat shields from protective packaging and place them on a non-abrasive surface such as a blanket or carpet. Using a non-permanent marker or tape, mark outside edge of each heat shield to show location of mounting clips that the hose clamps will loop through (Figure 4). 3. Apply a small amount of anti-seize compound to the threads of the stock O2 sensor and install it into the header assembly. NOTE: Be careful not to overtighten or get anti-seize compound on the sensor tip as this could damage or affect the sensor function. 4. Carefully lay header assembly into the heat shields and loosely install the hose clamps #20 on head pipe heat shields and #24 on collector heat shield (supplied) by feeding the tail end of the clamp into the heat shield clips. Take note of screw head direction (Figure 5), for adjustment purposes they must be accessible when system is installed. NOTE: Do not tighten the clamps at this time. 5. Using stock dome nuts, carefully install system into exhaust ports. (Assistance may be required). NOTE: Install but do not tighten the exhaust nuts at this time. 6. Remove the muffl er heat shield and baffl e assembly from their protective packaging. Place them on a non-abrasive surface such as a blanket or carpet. 7. Insert the large hose clamp (#56, supplied) into the clip on the muffl er heat shield. 8. Carefully slide the baffl e assembly (without damaging the fi berglass packing) into the muffl er heat shield and align the holes in the heatshield with those in the baffl e. Secure the baffl e with the 1/4-20 x 1/2″ button head screws (supplied) and tighten the hose clamp. 9. Install the 5/16″ x 1 1/4″ hex head bolt, washers and locknut (supplied) in the muffl er clamp (supplied) and slip the clamp over the end of the baffl e tube. 10. Slide nut plate (supplied) inside the bracket welded to backside of baffl e (Figure 6). 11. Install the muffl er assembly onto the collector, making sure it slides forward enough to align the edge of the bracket welded to the baffl e with the edge of the mounting bracket. 12. Attach the muffl er assembly to the mounting bracket using the 5/16″ x 5/8″ fl ange head bolts (supplied). 13. Tighten exhaust port nuts evenly on both cylinders. 14. Tighten the muffl er clamp and the 5/16″ fl ange head bolts, securing the muffl er assembly. 15. Insert the O2 sensor plug back into harness and tuck harness back into its original position. Reinstall the cover. 16. Check alignment of heat shields making sure the ends meet squarely to the collector heat shield. Tighten the hose clamps on all the heat shields when properly aligned. 17. Reinstall right side passenger and rider fl oorboards and tighten the 12mm bolts. 18. Check for adequate clearance between all exhaust system components and motorcycle accessories prone to heat damage. 19. All hardware must be properly tightened and the exhaust pipes thoroughly clean before starting motorcycle

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HARLEY DAVIDSON SPORTSTER BLACK EXHAUST HEAT SHIELDS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-02-2011

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INSTALLATION Remove Original Equipment (OE) Heat Shields Avoid contact with exhaust system and wear protective clothing that completely covers legs while riding. Exhaust pipes and mufflers get very hot when engine is running and remain too hot to touch, even after engine is turned off. Failure to wear protective clothing could result in burns or other serious injury. (00009a) 1. Allow the motorcycle to cool. 2. Identify the position of the OE clamp screws securing the black heat shields to the exhaust pipes. NOTE The clamp screws are positioned on either side of the exhaust pipe for clearance. 3. See Figure 1. Open the heat shield clamps (1) and spread the bands to remove front and rear heat shields (2) from the exhausts. Retain the heat shield clamps Install Black Heat Shields 1. See Figure 2. Matching the OE position of the heat shield clamps, open the clamps bands and thread the bands through the brackets of the front (1) and rear (2) black heat shields. 2. Spread the band around the exhaust pipes and push the end of the bands to engage the clamp screws. Tighten to hold the heat shields in place. 3. Adjust the shields and heat shield clamps to access clamp screws and to avoid contact with other components. 4. Tighten the heat shield clamp screws

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KAWASAKI VULCAN 700/750 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 28-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Place the bike on the center stand. 2. Remove the three clamps attaching the heat shield to the left hand head pipe and set the heat shield aside. 3. Remove the two heat shield clamps attaching the heat shield to the right hand head pipe and set the heat shield aside. 4. Loosen the pinch clamps where the mufflers slip onto the muffler box (the black box in front of the rear tire). Remove the bolt attaching the mufflers to the footrest. 5. Remove the left and right hand mufflers and set them aside. 6. Remove the right hand foot rest and brake pedal assembly from the frame. 7. Loosen the pinch clamps where the head pipes slip into the muffler box. 8. Remove the two nuts that secure the right head pipe to the cylinder head. Repeat this step on the left head pipe and save the nuts for reuse. 9. Remove the left and right hand head pipes. Remove the header flange from each head pipe and save the two flanges for reuse. Set the head pipes aside. 10. Remove the two bolts (one on each side) that mount the muffler box to the frame. Lower the muffler box down and set it aside. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Remove the two bolts from the charcoal canister mount, the canister is located in front of the rear tire. Using the two 6mm x 16mm bolts (supplied) install the centerstand stop bracket, (stamped 205), by aligning the holes in the bracket with the holes in the canister mount. Be sure the bend closest to the holes in the bracket angles towards the rear of the motorcycle and the tang is pointed to the left hand side. Tighten the two 6mm bolts at this time. 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 both heat shields. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns. Repeat this step with the rear heat shield. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. Leave them loose at this time. 3. Install a three hole mounting bracket to each muffler as shown in figure 1. Slide one dog bone shaped nut plate under the bracket that is welded to the backside of each muffler. Attach the mounting bracket using two of the 5/16″ flange head bolts (supplied), leave them loose at this time. Note : The muffler bracket stamped #284 is for the right hand muffler, bracket #285 is for the left hand muffler. 4. Install the rear exhaust assembly, with the heat shield attached, to the rear cylinder using the stock flanges and nuts. Install the stock muffler mounting bolts through the rear footrest brackets, the supplied muffler brackets, and finger tighten the nuts. Leave them loose at this time. 5. Repeat step #4 with the front head pipe

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YAMAHA VIRAGO 700/ 1100 2 into 2 EXHAUST SYSTEM REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 20-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the slip joint clamp on the front and rear head pipe, which are located at the muffler box. 2. Remove the two nuts that hold the front head pipe to the engine. Slip the head pipe out of the muffler box and set it aside. Note: Do not remove the rear head pipe, it has been incorporated in the design of the new exhaust system. 3. Remove the muffler box mounting bolt located in front of the passenger foot rest on the left side. 4. Remove two bolts from the right passenger foot rest assembly and set the foot rest aside. 5. Slide the muffler box off of the rear head pipe and set it aside. 6. Replace the muffler box mounting bolt (from step #3) using the washer and nut (supplied) on the back side. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Attach the mounting bar to the motorcycle frame behind the right passenger foot rest. Align the two holes in the largest bracket on the mounting bar with the two holes on the frame, be sure the bend in the mounting bar is pointing to the center of the motorcycle. 2. Install the round steel spacer (supplied) to the rear most hole in the bracket. 3. Attach the foot rest using the two 8mm x 1.25 x 25mm bolts (supplied). 4. Slide the new exhaust flange (supplied) onto the front head pipe. 5. Install the two heat shields to the front head pipe using the four hose clamps (supplied). 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 both heat shields. Place the heat shields onto the front head pipe. Note: Be sure the bend in the heat shield matches the bend in the head pipe exactly. Wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 6. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 7. Slide a chrome pinch clamp (supplied) onto the expanded end of the new rear head pipe. Install a 3/8″ x 1″ bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Repeat this step on the inlet end of each muffler using the two muffler clamps with 5/16″ x 1 1/4″ bolts (hardware supplied) but leave the clamp loose at this time. 8. Slip the new rear head pipe with the heat shield attached, over the stock rear pipe and gasket, but leave the clamp loose at this time. 9. Install the front head pipe, with the heat shield attached and stock gasket in place, to the front cylinder using the stock nuts, leave them loose at this time

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KAWASAKI VULCAN 800 STRAIGHT SHOT EXHAUST SYSTEM INSTALATION MANUAL

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Filed Under (Kawasaki) by admin on 28-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header flange nuts from the front and rear head pipes. 2. Remove the acorn nut located under the rear muffler. 3. Remove the two allen bolts located under the front muffler. 4. Remove the stock exhaust system from the motorcycle and set it aside. 5. Remove the two hex head bolts that attach the stock muffler mounting bracket to the frame of the motorcycle. Remove the muffler bracket and set it aside. 6. Remove the two rubber grommets and spacers from the stock muffler and the one grommet and spacer from the muffler mounting bracket. Set them aside with the the two mounting bolts, they will be reused during installation. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Install a chrome header flange onto the front and rear head pipes. 3. Install the heat shield to the front head pipe using the two hose clamps (supplied). 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 both heat shields. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 4. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time. 5. Install the rear head pipe, with the heat shield attached, to the rear cylinder using the stock nuts. Leave them loose at this time. 6. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 7. Slide one dog bone shaped nut plate under the bracket that is welded to each muffler. 8. Slide a chrome muffler clamp (supplied) onto the inlet end of each muffler. Install a 5/16″ x 1 1/4″ bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Do this to each muffler but leave the clamp loose at this time. 9. Install one muffler to the four hole bracket welded to the V&H mounting bar using the two 5/16″ flange bolts (supplied) and leave them loose. (See figure 1) 10. Slip the muffler and mounting bar assembly onto the front head pipe while aligning the grommet holes in the mounting bar with the holes in the frame.

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Harley-Davidson Sportster 883/ 1200 Straightshot HS Exhaust system REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 19-12-2010

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STOCK EXHAUST SYSTEM REMOVAL 1. Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts. 2. Remove the two head pipe mounting nuts from each flange, located at the cylinder head. 3. Remove the two bolts from each muffler body which attach the muffler bodies to the mounting bar. 4. Remove the clamp bolt which mounts the rear head Page 1 of 4 D445N Rev. 1.0 Sportster 883/1200 Straightshot HS Exhaust system Part #17815 U S A Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your VANCE & HINES exhaust system is designed and crafted for maximum performance, a perfect fit, a great sound and unbeatable style! Please follow the installation instructions below and if you have any questions, feel free to call our technical help line (562) 926-5291. Attention Installer: (if other than owner): Please forward this instruction sheet to the purchaser of this product. These instructions contain valuable information necessary to the end user. Tools required for installation: 3/16″ & 5/16″ Allen wrenches 3/16″ & 5/16″ Allen & 1/2″ sockets 3/8″ Ratchet & Extensions T30 Torx driver 1/2″ Wrench 5/16″ nutdriver/flat blade screwdriver Ft/lb. & In/lb. Torque wrenches Snapring pliers pipe to the belt drive cover bracket and carefully remove both exhaust pipes from the motorcycle. 5. Remove the drive belt cover and take the bracket off the rear cover bolt, it will not be re-used. 6. Loosen the brake rod at the rear eyelet using a T30 Torx driver. 7. Remove the exhaust mounting bar, saving the three mount bolts and washers for re-use. 8. Using snapring pliers, carefully remove the flanges and circlips from the stock exhaust system. Save for re-use. NOTE: If circlips look bent or twisted replace them with new circlips. VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Check condition of stock exhaust gaskets. Replace if damaged or worn. Vance & Hines recommends you replace your gaskets with Screamin’ Eagle gaskets part number 17048-98. 2. Install and tighten supplied mounting bracket (stamped 356-P) using stock bolts and washers (Figure 1). Torque to 30-33 Ft/Lbs. NOTE: Support the rear of the bracket during tightening to insure it is aligned with the bottom edge of the frame. 3. Re-install drive belt cover. Torque to 1 x 3/8″ bolt 30-33 Ft/Lbs. 2 x 1/4″ bolts 80-120 In/Lbs. 4. Re-install brake rod eyelet using blue thread locking compound (Loctite┬« 243). There is a 1/2″ clearance hole in the bracket to allow access for tightening brake rod eyelet. Torque to 120/180 In/Lbs. (Figure 1). 5. Remove header pipes 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 where hose clamps will loop through (Figure 2). 6. Install circlips and flanges from the stock system onto both new head pipes.

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KAWASAKI VULCAN 1500 PRO PIPE HS EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 28-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the mufflers by loosening the pinch clamps on the front of each muffler. 2. Remove the muffler mounting bolt from the right side passenger footrest, slide the mufflers off and set them aside. Note: Save the mounting bolt, it will be reused for installation. 3. Loosen the pinch clamp on both front and rear head pipes, they’re located at the resonance chamber (the black box where the pipes meet). 4. Remove the two acorn nuts that mount the head pipe to the cylinder head. Remove the two piece header flange and set it aside. 5. Remove the front head pipe by rotating it down and pull it out of the resonance chamber. 6. Remove the two acorn nuts and flange from the rear head pipe. Remove the two bolts from either side of the resonance chamber and lower rear pipe and resonance chamber down and out and set it aside. 7. Remove the rubber grommets at the resonance chamber mounting points. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Install the new mounting bracket (stamped 317) to the inside of the stock muffler mounting point (Refer to FIG. 1). 2. Unscrew all of the hose clamps (supplied) until they are completely loose. Mark the top edge of all three heat shields with the location of the mounting clips that are welded to the backside. Position the front heat shield over the head pipe and feed the tail end of the hose clamps into the clips. Be sure that each hose clamp is engaged with both clips. Repeat this step with the rear and collector heat shields. To facilitate the installation of the collector heat shield use a forward sliding motion from the rear of the collector. Do not force the collector heat shield directly onto the collector as damage to the heat shield will result. Note: the collector heat shield uses the 3/8″ wide clamps. 3. Rotate the hose clamps in the shields so that the screw drives are accessible. Tighten only finger tight at this time. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 4. Check to be sure that the stock exhaust gaskets are in good shape. If you have any doubts as to their condition, replace them. 5. Install the header with the heat shields attached, to the front and rear cylinders using the stock nuts and bolts. Leave them loose at this time. 6. Slide the chrome muffler clamp (supplied) onto the inlet end of the megaphone. Install the 5/16″ x 1 1/4″ bolt with a flat washer on either side of the clamp followed by the 5/16″ lock nut (hardware supplied). Leave the clamp loose at this time. 7. Slip the megaphone onto the head pipe collector, engaging the collector heat shield between the clamp and the outer slip joint tube. Slide one dog bone shaped nut plate under the bracket that

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KAWASAKI VULCAN 900 SLASH CUT STAGGEREDS INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 02-05-2012

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1. Attach mounting bracket 440-P to frame using two stock fl ange head bolts used on stock upper bracket (Figures 1 and 2). 2. Remove head pipes 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 (Figure 3). 3. Lay front header, and rear header into their head heat shields and muffl er body heat shields. 4. Install #20 hose clamps (supplied) on heat shields and #36 (supplied) on muffl er body heat shields by feeding tail end of clamps into heat shield clips (fi gure 3). Take note of clamp screw head direction (Figure 4). Screw heads must be accessible when system is installed on motorcycle for adjustment purposes. NOTE: Do not tighten at this time. 5. Using stock fl ange nuts, carefully install head pipes into exhaust ports. Assistance may be required. NOTE: Do not tighten at this time. 6. Slide nut plates inside bracket that is welded to backside of muffl er bodies (Figure 5). While holding nut plates in place, attach muffl er bodies to mounting bracket 440-P using two 5/16″x 5/8″ fl ange head bolts (supplied). Leave them loose at this time. 7. Align muffl er bodies so they are level and parallel when viewing from the right side of the bike. Tighten cylinder port exhaust fl ange nuts on front and rear cylinders. 8. Tighten the fl ange bolts on both muffl ers. 9. Tighten all heat shield clamps. 10. Check for adequate clearance of all exhaust system components and motorcycle accessories prone to heat damage. NOTE: For models with fl oorboards, two Spacer washers are supplied to space out the fl oorboard bracket enough to allow the fl oorboard to fold up without hitting the heat shield. 11. Be sure to tighten all hardware before starting your motorcycle. 12. After installation and before starting motorcycle, completely clean pipes and muffl ers with cleaning solvent and a clean, soft cloth that will not leave a residue. NOTE: Any residue, oil, or fi ngerprints will stain the chrome when the metal heats up

SUZUKI M109 1800 cc EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 10-11-2010

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System. 6. Remove the dust cover from the solenoid to expose the rotating cam and cables. DO NOT TRY TO ROTATE THE CAM RELATIVE TO THE ACTUATOR SELENOID TO REMOVE THE CABLES; DOING SO MAY DAMAGE THE INTERNAL COMPONENTS OF THE SOLENOID. To remove the cables from the cam, use the slack in the cables obtained in Step 5 to disengage the cable barrels from the cam, see Figure 1. THE DUST COVER WILL NOT BE REINSTALLED. 7. Now prepare the exhaust valve actuator solenoid for reuse. SECURELY HOLD THE CAM TO PREVENT IT FROM ROTATING IN THE SOLENOID. WHILE PREVENTING THE CAM FROM ROTATING, remove the 10 – 32 flange bolt securing it, see Figure 2. Replace the cam with the Cobra supplied cam, BE SURE TO PREVENT THE CAM FROM ROTATING WHEN REINSTALLING THE BOLT, OTHERWISE DAMAGE MAY OCCUR TO THE SOLENOID , see Figure 3. Torque to factory specifications.

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KAWASAKI VULCAN 800 CRUZER EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Kawasaki) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header flange nuts from the front and rear head pipes. 2. Remove the acorn nut located under the rear muffler. 3. Remove the two allen bolts located under the front muffler. 4. Remove the stock exhaust system from the motorcycle and set it aside. 5. Remove the two hex head bolts that attach the stock muffler mounting bracket to the frame of the motorcycle. Remove the muffler bracket and set it aside. 6. Remove the two rubber grommets and spacers from the stock muffler and the one grommet and spacer from the muffler mounting bracket. Set them aside with the the two mounting bolts, they will be reused during installation. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Install the heat shield to the front head pipe using the three hose clamps (supplied). 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 both heat shields. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 3. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 4. Be sure the steel spacers are in place in the center of the grommets. Install the two allen bolts (from removal step #3) through the mounting bracket and into the frame. Leave them loose at this time. 5. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time.

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