HARLEY DAVIDSON DYNA LongShot 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. Remove the two mounting nuts from each head pipe, located at the cylinder head. 3. Remove both front and rear head pipe clamp bolts. 4. Remove the entire exhaust system and set it aside. 5. 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. 6. Remove the rear head pipe clamp bracket from the transmission cover. Save the bolts, two will be reused. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Locate the muffler mounting bracket (stamped 239). Mount the bracket to the engine case, to the rear of the transmission cover using the two stock bolts. Refer to figure 1. Tighten the bolts at this time. Install the mounting bar (supplied) to the transmission housing using the stock hardware. Refer to figure 1 . Note: The mounting bracket should mount flatagainst the transmission housing. Some motorcycles use a stud to mount the stock rear head pipe clamp, be sure to remove the stud from the transmission housing and replace it when mounting the bracket, this will insure that the bracket is flat against the housing. 2. Locate the muffler clamp bracket (stamped 240). Install the bracket to the outside of bracket 239, using the 5/16″x 1 1/4″ bolt and 5/16″ flat washer (supplied). Refer to figure 1. Leave the bracket loose, it will be adjusted later. 3. 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. 4. Install the circlips and flanges from the stock system onto both the new head pipes. 5. Slide the new pipe clamp (supplied) onto the muffler end of the front head pipe. Position the clamp in the approximate mounting location on the pipe. 6. 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 rear head pipe.

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

YAMAHA ROAD STAR EXHAUST SYSTEM INSTALLATION MANUAL

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

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the header flange nuts from the rear cylinder. 2. Loosen the muffler clamp on the front head pipe. 3. Remove the two muffler mounting bracket bolts, located between the two mufflers. 4. Carefully separate the front head pipe from the muffler assembly. Remove the muffler assembly with the rear head pipe attached and set it aside. 5. Remove the header flange nuts from the front cylinder. Remove the front head pipe and set it aside. 6. Remove the muffler mounting bracket from the frame. Note: The rear brake hose must be disconnected from the rear brake caliper in order to remove the muffler mounting bracket. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Reconnect the brake hose to the rear caliper. Important : Bleed the rear brake to remove any air from the system and refill the reservoir with the proper brake fluid. 2. Install the new mounting bracket (stamped 273) to the frame, by aligning the two 10mm holes in the bracket with the two holes in the frame below the right rear footrest (where the stock mounting bar was removed). Use the two 10mm bolts and lock nuts (supplied), do not tighten at this time. Note: The bracket will bend away from the motorcycle when mounted correctly. Refer to figure 1. 3. Connect the brake hose clip to the muffler mounting bracket, using the 6mm bolt and lock nut (supplied). Refer to figure 1. 4. Install the chrome flanges (supplied) on to both the new head pipes. 5. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them.

HArley Davidson Sportster Sideshots 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 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 clamp bolt which mounts the rear head pipe to the belt drive cover bracket. 4. Remove the two bolts from each muffler body which Page 1 of 4 D465IN Rev. 1.0 Sportster Sideshots Exhaust system Part #26011 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: Wrenches – 9/16″ and 1/2″ Ratchet, 3/8″ drive and 9″ extension Torx sockets – T30 Sockets – 9/16″ and 1/2″ 3/16″ & 5/16″ Allen wrench 5/16″Nutdriver/flat blade screwdriver Snapring pliers attach the muffler bodies to the mounting bar 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.

HONDA VT1100 SHADOW EXHAUST SYSTEM Installation Manual

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

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REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header nuts from the exhaust port on both front and rear cylinders. The nuts will be reused during installation. 2. Remove the mounting bolts/nuts located below the lower muffler. Carefully remove the entire system and set it aside. Note: The system is heavy so have someone assist you. 3. Remove the muffler mounting bracket from the frame but save the two bolts for reuse. 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. Remove the bar bracket from the box. Hold the bar bracket in front of you with the four hole bracket positioned to the right hand side and pointing down. Mount one muffler to the bracket on the left hand side of the bar using two of the 5/16″ bolts (supplied) and leave them loose. Be sure the small end of the muffler is pointing to the right hand side. 3. Slide a chrome muffler clamp (supplied) onto the inlet end of each muffler. 4. Slide a new flange onto each header tube. Note: The two smaller holes in the header flanges are offset from the large hole. If the small holes do not align with studs at the exhaust port, spin the flange on the pipe one half of a turn and try again. Refer to Figure 1. 5. Place the head pipe into the heat shield, 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. Wrap the hose clamp around the head tube and give the screw three to four turns, leaving heat shield loose on the head pipe. Note : The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike

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

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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 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)

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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) .