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Kawasaki 2000- ZX-12R Ninja exhaust system Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Remove the lower fairing. Remove the lower radiator mounting bolts, loosen the upper bolts and pivot the radiator forward to provide access to the exhaust nuts (flange nuts). Remove the oil cooler mounting bolts and pivot the oil cooler forward to provide access. 2. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 3. Inspect the exhaust gaskets. Replace if necessary. 4. Assemble the head pipes 1, 2, 3, and 4 by matching the joints of the same color to the pair of front Y-pipes. Do not install the exhaust springs at this time. 5. Place a billet aluminum Mouthpiece ring Z on each TiForce head pipe. (see figure 3 for details) . 6. Attach the assembled head pipe sections to the exhaust ports, but do not tighten the flange nuts fully, allowing for some adjustment in the remaining steps. Reuse the flange nuts saved from step 2 above. Make sure the ends of the head pipes fit flush and snug in the ports and Mouthpiece ring Z before tightening. 7. Install the S-Bend to the front section of the head pipes and two Y-pipes. 8. Go back and retighten the head pipe flange nuts per factory specifications – make sure the head pipes and Mouthpiece ring Z are centered in each port. 9. Slide the TiForce end can into place. 10. Loosely attach the two rubber bands, stainless steel bands K, and stay / hanger G to the end can using the supplied 6mm hardware H. (See figure 1) . 11. Place the bands approximately 118 mm from the edge of the end can. (See figure 2) . 12. Using the stock provided mounting point on the passenger foot peg, and using the stock-mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 13. Attach the supplied springs to all the joints, starting from the head pipes and working back to the end can. 14. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance

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Kawasaki ZRX-1100 / 1200 exhaust system Installation Instructions

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Remove the existing exhaust system and save the flange nuts for reuse. Save the stock exhaust can mounting bolt and nut for reuse as well. 2. Inspect the exhaust gaskets. Replace if necessary. 3. Attach the head pipes 1, 2, 3 , and 4 to the exhaust ports of their respective cylinders, using the flange nuts saved from step 1 above. Loosely apply the flange nuts for now, allowing for ome adjustment. 4. Attach the Y-pipe collectors to the head pipes. Please note that one collector goes to pipes #1 and #4 and one collector goes to pipes #2 and #3 (collectors are labeled). Make sure the ends of the head pipes fit flush and snug in the ports. Do not install the springs at this time. 5. Install the S-Bend to the rear of the two Y-pipe collectors. Do not install the springs at this time. 6. Go back and retighten the head pipe flange nuts per factory specifications – make sure the head pipes are centered in each port. 7. Slide the TiForce end can into place on the S-bend pipe. 8. Loosely attach the two rubber bands, stainless steel bands K, and the stay / hanger G, to the end can using the supplied 6mm hardware H. (See figure 1) . Make sure that the rubber bands fully cover the stainless bands to prevent scratches to the can. 9. Place the bands approximately 108mm from the edge of the end can. (See figure 2) . 10. Go back and tighten the exhaust flange nuts per factory specification. Do not over tighten. 11. Using the stock provided mounting point on the right passenger footpeg, and using the stock mounting bolt, mount the end can loosely, allowing for some adjustment. Insert the stock mounting bolt through the stay / hanger G. 12. Attach the supplied springs to all the joints, starting from the head pipes and working back to the end can. 13. Make sure the exhaust system is free and clear, if necessary jiggle the system to adjust for proper clearance. 14. Carefully align the two stainless bands K so that they are parallel to each other, and spaced properly on the can (refer to step 11 / figure 2), then tighten the 6mm hardware H and the stock mounting bolt hardware. Make sure that the rubber pads fully cover the band(s). USE CAUTION WHEN TIGHTENING THE 6MM HARDWARE AND THE TWO BANDS SO AS NOT TO CRUSH OR DISTORT THE SLEEVE OF THE CAN. 15. Using some brake and contact cleaner on a clean rag, carefully wipe down the entire exhaust system to remove any residual oils, anti seize, fingerprints and dirt prior to starting the motor. FAILURE TO CLEAN THE TUBING AND CAN MAY RESULT IN PERMANENT STAINING OF THE SYSTEM WHEN HEATED. 16. Check that all hardware is properly tightened, and then start the motor and check for exhaust leaks

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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 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.

HONDA VF750 MAGNA SLIP-ON EXHAUST SYSTEM Installation Manual

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

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the left and right side frame covers to prevent damaging them. 2. Loosen the pinch clamps on the inlet end of all four mufflers, located behind the rear motor mount. 3. Remove the left and right front head pipes. 4. Remove the rear mounting bolt from both muffler assemblies. Carefully slide each muffler assembly off the head pipes and set them aside. 5. Replace the front head pipes. Note : Leave the head pipes loose for later adjustment. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. 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. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 2. Place the slip-on head tube into the matching heat shield, wrap the hose clamp around the head tube and give the screw three to four turns, leaving heat shield loose on the head tube. Repeat this step with opposite head tube and heat shield. 3. Slide a T-bolt band clamp (supplied) onto the slotted end of each slip-on tube. 4. Slip the slotted end of tube onto the rear head pipes. The shorter of the two slip-on tubes mounts on the right rear head pipe and the longer tube on the left rear head pipe. Tighten the T- bolt clamp until the pipe is snug but so the pipe will still be able to rotate. 5. Install the muffler mounting brackets to the frame using the single hole in the brackets and the stock hardware. The left side mounting bracket (stamped #206 on the bracket) mounts to the outside of the frame, where the stock muffler assembly mounted. The right side bracket (stamped #207) mounts to the inside of the frame, behind the stock muffler mounting point. 6. 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 (all supplied). Do this to each muffler but leave the clamp loose at this time. 7. To determine the difference between the left, right, upper and lower mufflers refer to the number stamped on the bracket welded to the backside of each muffler. The top right hand muffler is D500, the bottom right hand muffler is D510, the top left hand muffler is D550 and the bottom left hand muffler is D512. Note : The endcap bolts should face down and inward when viewing from the rear (Refer to Figure 1) .

DUCATI MONSTER S4R And DUCATI MONSTER S2R EXHAUST SYSTEM Installation instructions

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Filed Under (Ducati) by admin on 26-10-2010

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REMOVAL OF STOCK EXHAUST SYSTEM: 1. Put the motorcycle on a side stand, we recommend a racing stand. Make sure, that surface is solid and flat. 2. Remove stock heat shields (Figure 1, 2) 3. Unscrew the bolts from the metal clamps at the muffler – collector joints (Figure 3, 4). T-handle 10mm wrench T-handle 12mm wrench T-handle 13mm wrench T-handle 3mm three hexagon key wrench T-handle 5mm three hexagon key wrench Combination 13mm wrench Spring puller Figure 1 Figure 2 Figure 3 Figure 4
NAV – 124 3 Figure 10 Figure 7 Figure 8 4. Unscrew the bolt from the muffler chassis hanging bracket and remove both mufflers with link pipes (Figure 5, 6). INSTALLATION OF THE AKRAPOVIC SLIP-ON EXHAUST SYSTEM: 1. Slide the link pipes onto the stock collector (Figure 7) hand tighten the metal clamps at the Akrapovic link pipe – stock collector joints; coat the interior side of the metal clamps and the clamp bolts with Akrapovic anti-seizing copper paste (black tube) (Figure 8). 2. Install Akrapovic carbon-fiber chassis hanging bracket (Figure 9, 10). 22Nm 16ftlb Figure 5 Figure 6 Figure 9 NAV – 124 4 Figure 15 3. Position the muffler correctly and slide it onto the outlet side of the link pipes and attach the springs; WARNING! make sure, that springs pull the muffler all the way onto the link pipes – use rubber mallet if necessary to tap the connections into place! (Figure 11, 12). 4. Correctly position the carbon-fiber clamp and slide it onto the muffler – bear in mind the left offset of the carbon-fiber clamp viewed from the rear. WARNING: open the clamp slightly wider than the diameter of the outer sleeve of the muffler – do not scrape it along the muffler outer sleeve! (Figure 13). Tighten the carbon-fiber clamp onto the Akrapovic carbon- fiber chassis hanging bracket (Figure 14, 15). Make sure the link pipes or muffler are not touching the frame or any other part of the motorcycle.

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SUZUKI VZ800 MARAUDER SLIP-ON EXHAUST SYSTEM INSTALLATION MANUAL

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

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosenthe right hand side footrest assembly. 2. Loosenthe two head pipes at the cylinder head. 3. Loosen the muffler clamps, located on the inlet end of the mufflers. 4. Remove the two nuts that mount the lower muffler to motorcycle. Keep the two mufflers bolted together as an assembly. 5. Lift the muffler assembly up to clear the studs from the mounting holes. Pull the mufflers off the head pipes and set them aside. 6. Remove the two flanged steel spacers from the hole in the rubber cushions, where the stock muffler assembly mounted. Reinstall the steel spacers through the backside of the rubber cushions so the flanged end of the spacers are on the backside of the cushions, opposite of there original position. 7. Remove the rear most heat shields from both of the head pipes and set them aside. 8. Remove the stock exhaust gaskets from the ends of both pipes. The Vance & Hines slip-on does not use a gasket at the slip joint . 9. Install the new muffler mounting bracket (stamped with the # 233 ) to the front side of the two holes with the rubber cushions the two of the 5/16″x 1 1/4″ bolt and two 5/16″ lock nuts (hardware supplied) through the two holes in the bracket that are spaced farthest apart. When mounted correctly, the bracket should bend up and out from the motorcycle

Harley Davidson Sportster Straightshots HS Slip-on Exhaust system

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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. Loosen, but do not remove, the two head pipe mounting nuts from each flange located at the cylinder head. 3. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 4. Loosen the clamp holding the mufflers onto the head pipes. Page 1 of 4 D480IN Rev. 1.0 Sportster Straightshots HS Slip-on Exhaust system Part #16819 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: 1/2″ combination wrench 3/8″ drive ratchet and 9″ extension 9/16″ and 1/2″ sockets 5/16″ Nutdriver/flat blade screwdriver 5. Remove the two bolts from each muffler which attach the mufflers to the mounting bar. 6. Remove the mufflers by sliding them off the head pipes. 7. Remove the clamp from the nose of each muffler (these will be re-used when installing the new mufflers). 8. Remove the gaskets from the crossover ports on the stock mufflers. Inspect the gaskets and replace if damaged or worn (H-D part #65927-00). 9. Install crossover gaskets onto mounting bar on motorcycle. VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Remove mufflers and heat shields from protective packaging. 2. Slide the nut plate inside the bracket that is welded to the backside of each muffler body and attach the muffler bodies to the mounting brackets (stamped 379-P) using four 5/16″ x 5/8″ flange head bolts (supplied). Leave them loose at this time (Figure 1). 3. Slide stock exhaust clamp onto nose of each muffler. 4. Slide mufflers onto head pipes and align crossover port with gasket on mounting bar (Figure 2). Press into place on gasket. 5. Attach the muffler brackets to the stock mounting bar using four 5/16″ x 3/4″ hex head bolts, washers, and nuts (supplied). Leave them loose at this time (Figure 3). 6. Tighten cylinder port exhaust flange nuts on front and rear cylinders. 7. Install and tighten the clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 8. Align muffler and bracket so they sit level. Tighten the muffler mounting bolts and the bracket mounting bolts. 9. Tighten the clamp holding the muffler onto the head pipe.

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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HONDA AERO 750 Front/ Rear Exhaust System Removal And Installation Instruction

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Filed Under (Honda) by admin on 15-11-2010

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Remove your stock exhaust system and large muffler bracket. 2. Attach the supplied Cobra bar mount bracket to the outside of the frame using the stock M10 bolts & nut along with the supplied M10 nut (See figure 1). DO NOT TIGHTEN at this time. 3. Loosen and move the right side floorboard out of the way to ease installation of the exhaust. 4. Install the rear head pipe using the stock acorn nuts but DO NOT TIGHTEN at this time. 5. Slide one supplied clamp #27-61MSC onto each muffler and position as shown in Figure 2. 6. Slide the rear muffler over the rear head pipe. Place one slider bracket inside the muffler bracket with the flat side of the bracket against the muffler bracket (see figure 2) and install two 5/16 x 5/8 hex bolts thru mounting bracket , muffler bracket and into the slider brackets. 7. Repeat step 6 for front head pipe and muffler making sure the front and rear mufflers are parallel. 8. Unscrew the remaining hose clamps and feed the tail end of the clamp through the clips on the inside of the heat shields. The screw end of the hose clamp should be accessible for tightening but not visible when the heat shields are mounted to the pipes. 9. Place the heat shields onto the head pipes and align on muffler as shown in Figure 2. You may need to loosen the muffler bolts to adjust the position of the muffler to the heat shields. Snug the heat shield clamps onto the head pipes but DO NOT TIGHTEN at this time. Rotate the muffler clamps so they don’t interfere with the heat shields but are still accessible to tighten. 10. Tighten mount to frame and then the acorn nuts on the head pipes making sure to tighten evenly. Now, tighten the muffler clamps. (NOTE: If the muffler clamps are slid to far up on the muffler or past the three slots, the clamps will not tighten.) Next tighten mufflers to mount bracket. 11. Reinstall the right floorboard and tighten to factory specifications . 12. Make sure all hardware is tight before starting your motorcycle.

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