POWER - Vance & Hines
Contents
1. t 1 At the location where the stock mounting studs were removed Figure1 Use the nut plates and 5 16 x5 8 flange bolts supplied to attach the pipes Install bracket stamped 499 P supplied using two 3 8 x3 4 flange bolts to the bracket Figure 6 Do not tighten at this time O supplied Figure 1 9 Align pipes on motorcycle so the gap between the two muffler bodies is 2 Remove head pipes and heat shields from protective packaging Place each consistent from front to rear Figure 7 Tighten the exhaust port flange 2 heat shield on a non abrasive surface such as a blanket or carpet Using a nuts the 5 16 x5 8 flange bolts supplied and the 3 8 x3 4 flange bolts N Z felt tip pen mark outside edge of each heat shield to show location of hose supplied attaching the bracket to the frame 20 clamp mounting clips Figure 3 10 Using the 28 hose clamps supplied install the muffler heat shields A T m 3 Apply a small amount of anti seize compound to the threads of the oxygen Beginning with the D308HC on the front head pipe followed by the A X lt lt sensors and install them into the new head pipes Gray lead installed into D309HC on the rear head pipe Screw heads should be accessible for w the front head pipe and the black lead installed into the rear head pipe adjustment purposes Figure 4 Do not tighten at this time Lu it lt NOTE Be careful not to get anti seize on sensor tip it may affect sensor 11 Adjust all2. U lt L amp lt 2 0 pe 7 7 amp l l lt 3 8 x3 4 Flange bolts x 2 5 16 x5 8 Flange bolts x 4 PARTS NOT SHOWN 499 P Bracket x D782FC Front head pipe x D783FC Rear head pipe x D550HC Front heat shield x1 c TT TTT oo D783HC Rear heat shield x Nylon cable tie x D308HC Front muffler heat shield x1 D309HC Rear muffler heat shield x1 T gt O aN L k O WARRANTY Vance amp 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 finishes This warranty is limited to the repair or replacement of a product proven to be defective from normal use Vance amp Hines exhaust systems are designed to fit and operate on OEM motor and chassis This warranty does not cover any product subject to abuse misuse improper installation or modification Page 3 of 3 D880IN Rev 1 0
3. 6 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 A Flat blade screwdriver a a A 5 16 Nutdriver A 3 8 1 2 9 16 amp 14mm Combination wrenches Snap Ring Pliers 3 8 Ratchet extensions 1 2 amp 9 16 Sockets 3 4 Deep Socket TOOLS REQUIRED AN C7 READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION Next lift the muffler assembly up to release it from the crossover pipe and carefully remove the assembly from the motorcycle Remove the 9 16 nuts attaching the crossover exhaust mount bracket to the frame Pull lightly outward to free crossover mount and carefully remove the front muffler assembly and the crossover pipe from the motorcycle Using a 14mm wrench carefully remove the O2 sensors from the stock head pipes and save for re use with the new system Remove the two lower mounting studs from the frame Figure 1 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 and replace if damaged Recommended replacement P N 65324 83B FIGURE 4 Arrows indicate screwlhead direction D880OIN Rev 1 0 FIGURE 5 FIGURE 6 i FIGURE 7 2 _ FIGURE 8 CVOTON WY Rema E Right Side a Chrome Bolt Cover jr
4. Ses NOSE MORE POWER HARLEY DAVIDSON SOFTAIL BREAKOUT CVO BREAKOUT BIG RADIUS INSTALLATION INSTRUCTIONS PART 26065 mK gt O nt bad ari Ob ne Page 1 of 3 o o Rmmsiksug y a ne i EE Remove the seat locate the rear O2 sensor connector and unplug the sensor from the harness Remove the battery and feed the sensor cable end through the frame NOTE Pay attention to wire routing for re installation Refer to service manual for proper battery removal Unplug the front sensor located behind the rectifier from harness and feed the end of the wire through the frame freeing it from motorcycle To gain better access to the flange nuts on cylinder heads it is recommended that you remove the front and rear heat shields from the exhaust pipes and set them aside Remove the two mounting flange nuts from each head pipe located at cylinder head Remove the rear cylinder muffler assembly by first removing the two 1 4 flange head bolts from the underside of the rear muffler body 6 l 10 11 Mark mounting clip locations Congratulations you have purchased the finest exhaust system for your motorcycle on the market Your Vance amp 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 please call our technical support line at 562 92
5. heat shields for the best alignment at the seam where they meet function Figure 8 and tighten all the hose clamps wel Z 3 4 Lay head pipes into head pipe heat shields Figure 2 and loosely install the 12 Feed connector for the front oxygen sensor Gray through the frame and into o lt 20 hose clamps supplied into mounting clips Figure 3 NOTE Muffler the holder on the frame behind rectifier Plug the sensor into the stock wiring ZS heat shields will be installed after pipes are on the motorcycle Screw heads connector L should be accessible when system is installed on motorcycle for adjustment 13 Install a new nylon cable tie supplied to hold the wires onto frame in the U purposes Figure 4 Do not tighten at this time original location Lu A s 5 Install circlips and flanges from stock system onto both new head pipes 14 Feed wire for the rear O2 sensor through the frame and under the seat 6 For the CVO Models so equipped it is recommended that the swing arm Re install battery plug the sensor into the stock wiring connector bolt chrome cover right side with cutout be removed Figure 5 15 Be sure to tighten all hardware before starting motorcycle 7 Using stock flange nuts carefully install head pipes onto motorcycle Do not 16 After installation and before starting the motorcycle completely clean pipes tighten at this time and mufflers with cleaning solvent and a clean soft cloth that will not leave O a resid
6. ue NOTE Any residue oil or fingerprints will stain the chrome when Q the metal heats up EXHAUST CARE HELPFUL HINTS TO AVOID DISCOLORATION OF EXHAUST SYSTEM Li 1 When installing a new set of chrome pipes make sure your hands are clean and free of oil 2 Avoid long periods of idling as this can cause discoloration After installation thoroughly clean pipes with a soft cloth and cleaning solvent that will leave 3 Intake leaks can cause the engine to run lean and overheat this could lead to discoloration no residue chrome wax polish glass cleaner alcohol ammonia etc before starting the 4 Make sure there are no exhaust leaks at the junction of the exhaust pipes and cylinder head O motorcycle We recommend replacing gaskets if they are worn 13861 ROSECRANS AVENUE SANTA FE SPRINGS CA 90670 SALES 562 921 5388 TECHNICAL 562 926 5291 FAX 562 802 0110 VANCEANDHINES COM PLEASE NOTE Every effort is made for Vance amp 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 Page 2 of 3 D88OIN Rev 1 0 e eee SOFTAIL BREAKOUT CVO BREAKOUT INSTALLATION INSTRUCTIONS PART 26065 PACKING LIST O O 20 Hose clamps x 5 Nut plate x 2 28 Hose clamps x 4 LESS NOISE LU x 7 lt
Download Pdf Manuals
Related Search