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

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HONDA SHADOW AERO 750 STRAIGHTSHOT HS EXHAUST SYSTEM

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Filed Under (Honda) by admin on 03-11-2011

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Install mounting bracket (stamped 359-P) in the original bracket mounting position, using two 10mm bolts and
one 10mm nut (supplied)(Figure 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 the outside edge of each heat shield to show location of hose clamp mounting clips (Figure 3). 3. Slide flanges onto head pipes and lay head pipes into
heat shields. Loosely install hose clamps by feeding tail end of clamp into heat shield clips (Figure 3). Take note of screw head direction (Figure 4). Screw head should be accessible when system is installed on motorcycle for adjustment purposes. Use #20 hose clamps for head pipe areas and #28 hose clamps for muffler areas.
4. Using stock nuts, carefully install head pipes into exhaust ports (Assistance may be required). NOTE: Do not tighten at this time.

HARLEY DAVIDSON SOFTAIL FATBOY STRAIGHTSHOT HS SLIP ON INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 24-12-2010

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1. Remove the heat shield from the rear head pipe and the back heat shield (“Z” Shaped) off the lower head pipe. NOTE: Loosen the front heat shield hose clamp closest to this shield to facilitate its removal. 2. Loosen the clamps holding the muffl ers onto the head pipes. 3. Remove the 1/2″ bolts holding muffl ers onto support bar. 4. Slide both muffl ers towards the rear until they are free from the head pipes. NOTE: Assistance and the use of a penetrating lubricant may be required. 5. Remove the stock exhaust clamps from the nose of each muffl er (these will be re-used when installing the new system). QUIET BAFFLE FUELPAK VANCE & HINES EXHAUST SYSTEM INSTALLATION WHEN YOU KNOW THE DIFFERENCE 1. Using the 5/16″ x 3/4″ hex head bolts and washers (supplied) secure the mounting bracket (stamped 419-P)(supplied) to the stock muffl er support bar. NOTE: The bracket should be mounted with the notch facing the front of the motorcycle (Figure 1). 2. Remove muffl ers and heat shields from their protective packaging and place them on a non-abrasive surface such as a blanket, towel or carpet. 3. Carefully lay a muffl er assembly into each straight heat shield and loosely install the hose clamps (supplied) by feeding the tail end of the clamp into the heat shield clips. Note the direction of the screw heads with relation to the muffl er location (Figure 2). 4. Slide stock exhaust clamps onto the nose of each muffl er body. NOTE: Orient the clamp to enable access for tightening the nut after installation. 5. Slide upper muffl er assembly (with heat shield) onto the upper head pipe. Insert nut plate (supplied) into the bracket welded to the muffl er body (Figure 3) and secure to the mounting bracket using the 5/16″ x 5/8″ fl ange head bolts (supplied). 6. Repeat step 5 placing the lower muffl er assembly on the lower head

YAMAHA ROADSTAR 1600/1700 POWERSHOTS EXHAUST SYSTEM INSTALLATION MANUAL

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

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STOCK EXHAUST SYSTEM REMOVAL 1. Remove both frame covers. Remove the left cover first to access a bolt that holds the right side cover in place. 2. Remove right side floorboard assembly held in place by two bolts (Figure 1). 3. Remove exhaust port Allen nuts. 4. Remove Allen bolts securing rear muffler to exhaust system mounting bracket. 5. Remove complete exhaust system. Begin by lifting muffler out of mounting bracket locating hole (assistance may be required). 6. Check condition of stock exhaust gaskets. Replace if damaged or worn 7. Remove two bolts attaching stock exhaust mounting bracket to frame. 8. Remove hose clamp securing rear brake hose to exhaust mounting bracket. 9. Remove brake hose banjo bolt from rear caliper. 10. Slide hose out of loop in bracket. 11. Check condition of sealing washers on banjo bolt and replace if damaged or worn. 12. Reconnect brake hose to caliper (without bracket) and torque Banjo bolt to 25 lbs. ft. 13. Brake system must be bled or brake will not operate correctly. Refill reservoir after bleeding 1. Remove exhaust system and heat shields from protective packaging. Place exhaust 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 hose clamps will loop through (Figure 2). 2. Attach brake hose clamp to mounting bracket (stamped 362-P) using one 6x16mm flange bolt and nylock nut (supplied) to tab located on top of bracket (Figure 2). 3. Install mounting bracket using two 10x30mm Allen bolts and lock nuts (supplied)(Figure 3). 4. Carefully slide heat shields onto headers.

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Harley Davidson V-ROD Powershots Exhaust System Installation Manual

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

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STOCK EXHAUST SYSTEM REMOVAL 1. Loosen nose slip clamp at front of muffler section using 12mm socket. 2. Remove pin located on mounting bracket from stock exhaust system using 13mm wrench and 4mm Allen wrench. 3. Remove two 6mm Allen bolts connecting lower muffler to mounting bracket. 4. Remove the entire muffler section from the headers as a single unit. Note: Do not remove stock mount bracket, rubber mount rail or head pipes from motorcycle, since they will be re-used. 5. Loosen the exhaust port flange bolts at both cylinders without removing. This will aid in the assembly and alignment of the new system 6. Remove the OEM nose slip clamp from the front of the OEM muffler section. Save for re-use. VANCE & HINES EXHAUST SYSTEM INSTALLATION 1. Remove exhaust system and heat shields from protective packaging. Place exhaust on a non-abrasive surface such as a blanket or carpet. Using a nonpermanent marker or tape, mark outside edge of each heat shield to show location of mounting clips that hose clamps will loop through. 2. Install OEM nose slip clamp to front of Vance & Hines muffler section. 3. Loosely install tailpipe heat shields (part # D285HC and D286HC) to headers using four #20 hose clamps and one #56 hose clamp. Note position and direction of clamp heads. (Figure 1) Note: #56 hose clamp attaches both heat shields

HARLEY DAVIDSON SOFTAIL DUALS AND SLIP ONS INSTALLATION MANUAL

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

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1. Attach mounting brackets 430-P on the left side and 431-P on the right side of the frame using two 3/8″ x 3/4″ fl ange head bolts on each one (supplied)(Figure 1). If equipped, plastic plugs must be removed. 2. Remove left foot peg and attach support bracket 428-P (Figure 1) using the stock bolt. Discard spacer if equipped. Do not tighten at this time. NOTE: On FLSTN models the passenger footpeg bracket should be removed. 3. 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 2). 4. Lay front head pipe, rear head pipe and muffl ers into their heat shields. 5. Install #20 hose clamps on heat shields and #28 on muffl er heat shields by feeding tail end of clamps into heat shield clips (Figure 2). Take note of clamp screw head direction (Figure 3). Screw heads must be accessible when system is installed on motorcycle for adjustment purposes. NOTE: Do not tighten at this time. 6. Install exhaust port fl anges and circlips from stock system onto head pipes (Figure 4). 7. Apply a small amount of anti-seize compound to the threads of one of the oxygen sensors and install it into front head pipe. NOTE: Be careful not to get anti-seize on sensor tip, it may affect sensor function. Do not install rear sensor at this time. 8. Disconnect front mount on shift lever rod to allow installation of rear head pipe (Figure 7). 9. Using stock fl ange nuts, carefully install head pipes into exhaust ports. Assistance may be required. NOTE: Do not tighten at this time. 10. Remove ignition coil cover to have open access to install rear sensor. 11. Install rear sensor using same instructions as step 7. Feed connector for rear oxygen sensor through frame and under the oil tank. Plug the sensor into stock wiring connector. 12. Slide a #59 T-bolt clamp (supplied) onto slotted end of left pipe. Slide slotted end onto head pipe tail (Figure 5). Align pipe with bracket 428-P previously installed in step 2. Install a #60 T-bolt clamp (supplied) by removing the nut and feeding the tail end through bracket hole (Figures 1 and 5). NOTE: Orient the clamp so that you can

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.

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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