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HARLEY DAVIDSON DYNA STREET PERFORMANCE SLIP-ON ACCESSORY MUFFLERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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PRODUCT INFORMATION Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. Noise Emission Warranty Harley-Davidson warrants that these mufflers, at the time of sale, meets all applicable United States E.P.A. Federal noise and Emissions standards. This warranty extends to the first person who buys these mufflers for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances. INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 2. Loosen stock muffler clamps and remove nuts that attach mufflers to muffler support tube. Remove stock mufflers. Save all mounting hardware for reinstallation. 3. Install new kit mufflers using muffler clamps (purchased separately) and stock mounting hardware saved from Step 2. Do not tighten hardware at this time. NOTE Before tightening nuts that attach mufflers to muffler support tubes, make sure the front muffler is positioned as far forward in its brackets slot as possible. This will eliminate any possible contact between the mufflers. 4. Tighten muffler clamp bolts to 45-60 ft-lbs (61-81 Nm) . Tighten nuts that attach mufflers to muffler support tube snugly. 5. Connect the negative (-) battery cable

HONDA SHADOW ACE TOURER 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. Loosen the pinch clamp bolt on the left hand muffler crossover pipe. (Located on the right of the motorcycle, where both mufflers merge with the head pipes). 2. Remove the two 8mm bolts that mount the left hand muffler to the frame. Drop the muffler down to clear the mounts and pull out from the collector. 3. Remove the right hand frame cover to avoid damaging it. 4. Remove the 8mm nut holding the head pipe flanges to the cylinder heads. Remove the 8mm bolts that mount the right hand muffler to the frame. 5. Remove the remainder of the exhaust system from the motorcycle and set it aside. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Be sure to check that the stock exhaust gaskets are in good shape. If you have any doubts as to their condition, replace them. 2. Install the chrome exhaust flanges (supplied) over the front and rear head pipes. 3. Install the rear head pipe to the rear cylinder using the stock 8mm acorn nuts. Route the pipe approximately 3/4″ beneath the swingarm, leaving the nuts finger tight at this time. 4. Install the front head pipe to the cylinder head using the stock 8mm acorn nuts. Its routing follows the stock head pipe, leave the nuts finger tight at this time. 5. Your Vance & Hines mufflers use the stock mounting locations and rubber grommets. Remove the steel spacers and rubber grommets from your stock mufflers and install them into Vance & Hines mufflers in the same locations. 6. Slip a chrome muffler clamp onto the inlet end of each muffler. Install the clamp hardware as shown in figure 1 (hardware supplied). Leave them loose at this time. 7 Slide the left hand muffler assembly (stamped H641) onto the rear head pipe approximately two inches. Mount the mufflers to the motorcycle using the stock bolts, in the stock locations. 8. Repeat the above step with the right hand muffler (stamped H640). 9. Unscrew all of the hose clamps (supplied) until they are completely loose. Mark the top edges of the heat shields with the location of the mounting clips that are welded to the back side of the heat shield. Position the right rear heat shield (stamped H226) over the rear head pipe and feed the tail end of the hose clamps into the clips. Be sure that each clamp is engaged into both clips. Repeat this procedure with each heat shield.

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.

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HARLEY DAVIDSON DYNA SLIP-ON ACCESSORY MUFFLERS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect negative (-) battery cable. Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 2. Loosen stock muffler clamps and remove nuts that attach mufflers to muffler support tube. Remove stock mufflers. Save all mounting hardware for reinstallation. -J04263 3. Install new kit mufflers using muffler clamps (purchased separately) and stock mounting hardware saved from Step 2. Do not tighten hardware at this time. NOTE Before tightening nuts that attach mufflers to muffler support tubes, make sure the front muffler is positioned as far forward in its brackets slot as possible. This will eliminate any possible contact between the mufflers. 4. Tighten muffler clamp bolts to 45-60 ft-lbs (61-81 Nm) . Tighten nuts that attach mufflers to muffler support tube snugly. 5. Connect the negative (-) battery cable

HARLEY DAVIDSON SOFTAIL MUFFLER SLIP-FIT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-04-2011

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1. Disconnect negative battery cable. Perform this installation when the engine is cool. Installing these mufflers when the engine is hot could cause burns which could result in moderate to minor injury. 2. Remove mufflers according to applicable Service Manual instructions. Shotgun exhaust mufflers will come off the vehicle as a pair, attached together. Staggered dual mufflers will come off the vehicle attached to the interconnect tube. 3. For a shotgun exhaust, skip to Step 6. 1 CAUTION 1 WARNING 1 WARNING 1 of 2 4. Remove mufflers from interconnect tube and discard gaskets and mufflers. 5. Install mufflers to interconnect pipe using new gaskets (6) and existing screws. Slip muffler clamps (1) on mufflers and install assembly back on vehicle. Tighten screws to 96-120 in-lbs (10.8-13.6 N-m). Tighten muffler clamps to 45-60 ft-lbs (61-81.3 Nm). Attach the interconnect tube to the frame using the existing flange lock nuts and washers. Tighten to 30-33 ft-lbs (40.7- 44.7 Nm). 6. On shotgun style assemblies, assemble top and bottom mufflers using interconnect seal. Torque screws to 96-120 in-lbs (61-81.3 Nm). Attach interconnect tube to frame using existing flange locknuts and washers. Torque to 30-33 ft-lbs, (40-7-44.7 Nm). 7. Replace fasteners and tighten as follows: muffler clamps to 45-60 ft-lbs (61-81.3 Nm), flange locknut on carriage bolt to 30-33 ft-lbs (40.7-44.7 Nm) and tighten screws and washers to 15-19 ft-lbs (20.3-25.8 Nm). 8. Reconnect negative battery cable. Tampering Prohibition Federal law prohibits any modification to this exhaust system which causes the motorcycle to exceed the Federal noise standard. Use of the motorcycle with such a modified exhaust system is also prohibited. Noise Emission Warranty Gabilan Manufacturing, Inc. warrants that these mufflers, at the time of sale, meet all applicable United States E.P.A. Federal noise standards. This warranty extends to the first person who buys these mufflers for purposes other than resale, and to all subsequent buyers. Warranty claims should be directed to an authorized Harley-Davidson Dealer. NOTE This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

VANCE And HINES MOTORSPORTS SUPERCHARGER Installation Manual

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Filed Under (Tips and Review) by admin on 27-10-2010

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Installation is complete in eight hours or less and no additional engine modiÞcations are required.* Simply remove the standard air box, injector bodies, water pump and a few hoses. The supercharger and plenum chamber Þt into the same location, with the drive belt and cover attaching to existing bolt holes in place of the original water pump housing. The only change to the engine is the removal of the water pump housing and drive shaft. A longer shaft and strengthened housing are supplied, which provide the output shaft for the Supercharger drive belt. The complete kit includes; What you get is an instant 35-40% increase in Power and Torque. The Þnished installation is deceptively simple; a clean looking, reliable motorcycle with unrivaled grunt, power and enhanced engine sound. When compared to a Turbo application, the Supercharger provides far greater volumetric efÞciency with no turbo lag or heat build-up. This kit provides smooth Òalways onÓ power for both Street and Strip use. The Supercharged V-Rod pulls cleanly from idle, and top gear roll-ons are impressive at any speed. Order yours today and put a smile on your face every time you ride

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Fitting new GL1500 Mufflers Installation Manual

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Filed Under (Honda) by admin on 08-04-2011

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The stock mufflers on the GL1500 Goldwing tend to rust after a few years. It doesn’t really matter how much you clean them because the design means that they tend to collect condensation which turns into water, then the dreaded tinworm rots them from the inside out. There is a drain hole in each muffler (near the front) to allow some water out, but the hole is really in the wrong place as the mufflers almost always rot at the ends near where the tailpipe is welded on. Replacing mufflers on the GL1500 Goldwing is easy enough and you really don’t need a tutorial for the task. But I did have a camera handy on the day I did the job so you may as well have the benefit of the images. This is a common sight on a GL1500 Goldwing. The mufflers rot from the inside out and eventually the ends just blow off. Believe it or not, these mufflers are on a 1997 GL1500SE with only 7,700 miles that was always stored in a dry garage! I replaced them in April 2004 and they had been almost as bad as this since 2002, but the owner of the Goldwing wasn’t using it much so he didn’t bother replacing them until 2004

Harley Davidson Touring/ Dresser Slip-on Exhaust System REMOVAL AND INSTALLATION MANUAL

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

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove both left and right saddlebags and set them aside. 2. Loosen the bolt from the pinch clamp on the front end of each muffler. Note: On the older model Dresser, spread the clamps just enough to remove them. 3. Remove the two 5/16″ bolts that mount the muffler to the saddlebag supports. Repeat this step on the opposite muffler. 4. Remove the stock mufflers and set them aside. Note: It may be necessary to use a penetrating lubricant to loosen the muffler from the head pipe. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Install one muffler clamp (supplied) over the front (notched end) of each muffler. 2. Slip the muffler over the stock head pipe, mount the muffler to the saddlebag support using the two stock 5/16″ bolts and tighten. Note : There is a different muffler for the left and right side of the motorcycle. The dent in each canister should always be facing in. This is to allow clearance for the swingarm. 3. Tighten the two muffler clamps. (Torque Specification 12 ft/lbs.) 4. Replace the saddlebags. 5. 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. For fuel injected models, we recommend the use of Vance & Hines Fuelpak part number 61003. PLEASE NOTE: Every effort is made for Vance & Hines Exhaust Systems to provide improved cornering clearance. However, due to design and space limitations on some motorcycle models, ground and cornering clearance may not be improved and in some cases may be reduced. Be sure to follow proper installation instructions

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

Suzuki INTRUDER 1400 SLIP-ON EXHAUST SYSTEM Installation Manual

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

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosenthe mounting bolt and pinch clamp on both left and right hand mufflers. 2. Loosenthe clamp on the crossover tube, located between the two mufflers. 3. Remove the two nuts that mount the front head pipe flange to the cylinder head. 4. Remove the two nuts that mount the rear head pipe flange to the cylinder head. 5. Remove the head pipes using a twisting motion to break the seal at the muffler and to clear the cylinder head. Note : If the exhaust coupler gaskets did not remain in the mufflers, remove them from the head pipes at this time. These coupler gaskets will not be reused in your new exhaust system. 6. Remove the mounting bolt from the left hand muffler. Remove the muffler, again using a twisting motion to seperate the crossover tube and set the muffler aside. (Save the stock mounting hardware for reuse). 7. Repeat step #6 on the the right hand muffler. Set the muffler aside. 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. Reinstall the stock head pipes to the engine. Note : Leave the flange nuts loose at this time. 3. Remove the mufflers from their boxes. There are a left and right hand muffler in this system. To define the difference between the left and right mufflers, check the bracket that is welded to the back side of the muffler. Each muffler is stamped with it’s own part number. Part # D500 is the RIGHT muffler and Part # D550 is the LEFTmuffler. 4. Install a three hole mounting bracket to each of the mufflers. 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 : Each muffler bracket has a number stamped on it, #179 bracket is for the left hand muffler and #180 is for the right hand muffler. When the brackets are mounted correctly, the end of the bracket with the single hole should point to the inlet end (small end) of the muffler. Refer to figure 1.