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Vance and hines 26071 User manual

STOCK EXHAUST
SYSTEM REMOVAL
TOOLS
REQUIRED
HARLEY-DAVIDSON®DYNA
BIG RADIUS 2-2
INSTALLATION INSTRUCTIONS
PART# 26071
1. Remove seat to gain access to rear oxygen sensor connector. Unplug
sensor and feed end of wire through frame so that it is free from
motorcycle. NOTE: Pay attention to wire routing for re-installation.
2. For 2006 to 2011 models remove two bolts holding rectier onto front of
frame (near front tire). Open plastic cover to gain access to front oxygen
sensor connector. Unplug sensor from ahrness and feed end of wire
through to free it from motocycle. For 2012 to later models the connector
is located under the rectier at the front of the motorcycle.
3. Loosen heat shield clamps on both the front and rear head pipes.
4. Remove front head pipe clamp bolt.
5. Remove the bolt that attaches rear head pipe clamp to mounting bar.
6. Remove two cylinder exhaust port ange nuts from each head pipe,
located at the cylinder head.
7. Remove the complete exhaust system and set aside. Assistance may be
required.
8. Remove stock mounting bar and the studs in the transmission cover.
9. Remove left bolt below the transmission cover. Position mounting bracket
391-P over mounting location to determine which bolts to remove (Figure
1). Install this bolt in the top hole left vacant by the new bracket.
10. Carefully remove the anges and circlips from the stock exhaust system us-
ing snapring pliers. NOTE: Replace bent or damaged circlips.
11. Remove stock exhaust gaskets and replace them with the supplied
exhaust gaskets. NOTE: Replacement gaskets HD Screaming Eagle
#17048-98 or equivalent
12. Remove stock oxygen sensors and set them aside for they will be re-used
on new system.
BRACKET 391-P
TRANSMISSION COVER
REMOVE ALLEN BOLT
PRIOR TO INSTALLING
MOUNTING BRACKET
USE 5/16"-18 X 1-1/2" HEX
BOLTS AND WASHERS (SUPPLIED)
USE 5/16-18 x 2.0" HEX BOLT
AND WASHER (SUPPLIED)
INSTALL ALLEN BOLT REMOVED
FROM LOWER HOLE
INSTALL SPACER BETWEEN
BRACKET AND MOTOR
D942IN Rev. 1.0
FIGURE 1
READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION
Page 1 of 4
Flat blade screwdriver
and #3 Phillips Head
5/16” Nutdriver
1/2”, 3/4”, 7/8”, 14mm,
22mm Combination
wrenches
3/16” & 1/4”
Allen wrenches
Snapring pliers
3/8” Ratchet &
extensions
1/2” Socket
7/16 & 9/16 Deep
Sockets
FIGURE 2
Installing
circlip
Flange
MORE POWER : LESS NOISE
Congratulations, you have purchased the nest exhaust system for
your motorcycle on the market. Your Vance & Hines exhaust system is
designed and crafted for maximum performance, a perfect t, a great
sound and unbeatable style. Please follow the installation instructions
below and if you have any questions, please call our technical support
line at (562) 926-5291.
Attention installer (if other than owner), please forward this instruction
sheet to the owner of this product. These instructions contain valuable
information to the end user.
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.
VANCE & HINES EXHAUST SYSTEM
INSTALLATION
1. Attach mounting bracket 390-P to transmission and tighten to 12-15 Ft/Lb
torque. (Figure 1). NOTE: 2006 to 2007 models use three 5/16” x 1-1/2” hex
head bolts and washers. 2008 to 2011 models use three 5/16” x 1-1/2” hex
head bolt, washers, 11/16” spacer between the bracket and transmission in
top hole. 2012 and later models use one 5/16” x 2” hex head bolt, washers
11/16” spacer in top hole and two 5/16” x 1-1/2” hex head bolts and
washers in remaining holes.
2. Remove head pipes from their protective packaging and install circlips and
anges from the stock system onto both new head pipes (Figure 2).
3. Apply a small amount of anti-seize compound to the threads of the oxygen
sensors and install them into the new head pipe.
NOTE: 2006 to 2011 models or models using 18mm wideband oxygen sensors
install sensor directly into head pipe. 2012 to later models install supplied
18mm to 12mm oxygen sensor adapter then install 12mm oxygen sensors
(Grey connector into front head pipe, Black connector into rear head pipe.)
4. Remove heat shields from their 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 hose clamp
mounting clips (Figure 3).
5. Lay head pipes (D418FC & D419FC) into head pipe heat shields (D400HC
& D403HC) respectively. Make sure alignment clip on head pipe ts inside
heat shield. Loosely install #20 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. NOTE: Do not tighten at this time.
6. Using stock ange nuts, carefully install head pipes into exhaust ports, starting
with the rear cylinder. Assistance may be required. NOTE: Do not tighten at
this time.
7. Slide nutplates inside brackets that are welded to backside of each mufer
body (Figure 5). While holding nutplates in place, attach mufer bodies to
mounting bracket 391-P using four 5/16”x 5/8” ange head bolts (supplied).
Leave them loose at this time.
8. Align pipes on motorcycle so that the gap between the two mufer bodies is
consistent from front to rear and tighten exhaust port ange nuts (Figure 6).
9. Tighten ange bolts securing mufer bodies to mount bracket 391-P.
10. Using the #28 hose clamps install the mufer heat shields with the D308HC on
the front head pipe and the D309HC on the rear. Take note of screw head
direction (Figure 4). NOTE: Do not tighten at this time.
11. Adjust the heat shields to get the best alignment at the seam where they
touch (Figure 6) and tighten all the hose clamps.
12. Feed wire for front oxygen sensor through frame and into plastic holder on
frame. Plug sensor into stock wiring connector. Snap plastic holder closed to
hold connector in place.
13. Put toothed edge of wiring holder into slot in frame. Re-install rectier so that
it ts under tooth of wiring holder, keeping it in place in frame. Tighten both
bolts.
14. Feed connector for rear oxygen sensor through frame and into underseat
compartment. Plug sensor into stock wiring connector.
15. Re-install seat.
16. Check for adequate clearance between all exhaust system components
and motorcycle accessories prone to heat damage.
17. Be sure to tighten all hardware before starting your motorcycle.
18. After installation and
before
starting motorcycle, completely clean pipes
and mufers with warm soapy water and a clean soft cloth that will not
leave a residue. NOTE: Any residue, oil, or ngerprints will stain the chrome
when the metal heats up.
EXHAUST CARE - HELPFUL HINTS TO AVOID DISCOLORATION OF EXHAUST SYSTEM
FIGURE 3 FIGURE 4 FIGURE 5 FIGURE 6
D942IN Rev. 1.0Page 2 of 4
Installing
hose clamp
Mark outside
edge
Arrows indicate clamp
screw head direction
Installing nutplate Align gap between mufers
FUELPAK
MORE POWER : LESS NOISE
1. When installing a new set of chrome pipes, make sure your hands are clean and free
of oil. After installation, thoroughly clean pipes with warm soapy water and a soft
cloth. Dry with clean towel to remove any residue (chrome wax / polish, glass cleaner,
alcohol, ammonia, etc...) before starting the motorcycle.
2. Avoid long periods of idling as this can cause discoloration.
3. Intake leaks can cause the engine to run lean and overheat, this could lead to
discoloration.
4. Make sure there are no exhaust leaks at the junction of the exhaust pipes and cylinder
head. We recommend replacing gaskets if they are worn.
VANCE & HINES OPTIONAL ACCESSORIES
FUEL MANAGEMENT:
Take the guess work out of fuel injection with Fuelpak Fuel
Management. Contact your local dealer or call (562) 921-
0071 to order. Visit fuelpak.com for more information.
Fuelpak is intended for racing or off-highway use only,
and is not legal for sale or use in California on pollution-
controlled vehicles.
ALL PARTS SHOWN ARE ACTUAL SIZE
PACKING LIST
Vance & Hines exhaust systems are warranted against defects in material and workmanship for a period of 90 days from the date of purchase from an authorized dealer. This warranty
does not cover discoloration of chrome nishes. This warranty is limited to the repair or replacement of a product proven to be defective from normal use. Vance & Hines exhaust systems
are designed to t and operate on OEM motor and chassis. This warranty does not cover any product subject to abuse, misuse, improper installation or modication.
WARRANTY
PARTS NOT SHOWN:
391-P Bracket x 1
D418FC Front head pipe assy x 1
D419FC Rear head pipe assy x 1
D400HC Front heat shield x 1
D403HC Rear heat shield x 1
D308HC Ft. mufer heat shield x 1
D309HC Rr. mufer heat shield x 1
HARLEY-DAVIDSON®DYNA
BIG RADIUS 2-2
INSTALLATION INSTRUCTIONS
PART# 26071
D942IN Rev. 1.0Page 3 of 4
#28 Hose clamps x 4 #20 Hose clamps x 5
5/16” x 5/8” Flange head bolts x 4
5/16” x 2.0” Hex head bolts x 1
5/16” Flat washers x 3
Nutplates x 2
11/16” x 9/16”
Spacer x 1
MORE POWER : LESS NOISE
5/16” x 1-1/2” Hex head bolts x 3
Exhaust Gaskets x 2
D942IN Rev. 1.0
Page 4 of 4
13861 ROSECRANS AVENUE / SANTA FE SPRINGS, CA 90670
SALES: (562) 921-7461 / TECHNICAL: (562) 926-5291 / FAX: (562) 802-0110
VANCEANDHINES.COM
MORE POWER : LESS NOISE
FUEL MANAGEMENT
NOW YOU NEED FUELPAK.
Your fuel injected Harley-Davidson® is equipped with an ECU
(electronic control unit) that’s programmed to deliver fuel to the motor
based on an air/fuel ratio for a stock air filter and stock exhaust
system. When you install a performance exhaust system, your
airflow changes, so you need a fuel management system that
adjusts your air/fuel ratio to match the changes. That fuel
management system is Fuelpak. Fuelpak adds and takes
away fuel, allowing for a more precise range of refinement
in your air/fuel ratio. Get the perfect fuel management
combination with your Vance & Hines exhaust system, get
Fuelpak. For more information visit the tuning center at fuelpakfi.
com
NOTICE: Fuelpak is intended for racing or off-highway use only, and is
not legal for sale or use in California on pollution-controlled vehicles.
GET THE MOST OUT OF YOUR RIDING EXPERIENCE...
AN AFTERMARKET EXHAUST SYSTEM IS ONLY YOUR FIRST STEP, NOW YOU NEED FUEL MANAGEMENT.

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