Vance & Hines Big Radius 2-Into-2 Full System Exhaust

Introduction

This manual provides essential information for the proper installation, operation, and maintenance of your Vance & Hines Big Radius 2-Into-2 Full System Exhaust. Adhering to these instructions will ensure optimal performance and longevity of your exhaust system. Please read this manual thoroughly before beginning installation.

Safety Warning:

Always wear appropriate personal protective equipment during installation. Allow the motorcycle and exhaust components to cool completely before handling. Exhaust systems can become extremely hot and cause severe burns. Ensure the motorcycle is stable and secure before performing any work.

Setup and Installation

The Vance & Hines Big Radius 2-Into-2 Full System Exhaust is designed for a precise fit on compatible Harley Davidson models. The system includes all necessary mounting hardware and features a 2-1/2 inch full header and muffler heat shield system, engineered to be virtually blue-proof, maintaining the chrome finish.

Pre-Installation Steps:

1. Ensure the motorcycle is turned off, cool, and on a stable stand.
2. Gather all tools required for exhaust removal and installation.
3. Carefully unpackage the new exhaust system and verify all components are present according to the packing list.

Installation Procedure:

1. Remove the existing exhaust system from the motorcycle, following the manufacturer's guidelines.
2. Install the new Vance & Hines headers, ensuring proper alignment with the engine's exhaust ports. The system includes mounts for factory O2 sensors as required; ensure these are correctly connected.
3. Attach the muffler sections to the headers. The system features beautifully curved 2-1/2 inch full-coverage heat shields and artistically scalloped end-tips.
4. Secure all mounting hardware. Do not fully tighten bolts until the entire system is loosely assembled and aligned.
5. Once aligned, progressively tighten all bolts to the manufacturer's specified torque settings.
6. Double-check all connections for security and proper fitment.

Image: The Vance & Hines Big Radius 2-Into-2 Full System Exhaust, model 26007, shown installed on a blue Harley Davidson motorcycle. The chrome finish and curved design are visible, highlighting the full system's integration with the motorcycle's aesthetics.

Operating Considerations

After installation, it is recommended to perform a short break-in ride to allow the exhaust system to settle and heat cycle. During this initial period, listen for any unusual noises or exhaust leaks. The Big Radius exhaust produces a signature hot-rod sound, which is a characteristic of its performance design.

Maintenance

Regular maintenance will help preserve the appearance and functionality of your Vance & Hines exhaust system.

Cleaning:

• Clean chrome surfaces regularly with a non-abrasive chrome cleaner and a soft cloth. Avoid harsh chemicals or abrasive pads that can scratch the finish.
• Ensure the exhaust is cool before cleaning.

Inspection:

• Periodically inspect all mounting hardware for tightness. Vibrations from motorcycle operation can cause fasteners to loosen over time.
• Check for any signs of exhaust leaks, such as black soot around connections.
• The system includes removable baffles. If desired, these can be removed for a louder sound profile or reinstalled for a more moderate tone. Refer to specific instructions for baffle removal/reinstallation.

Troubleshooting

If you encounter issues with your exhaust system, consider the following:

• Excessive Noise or Rattle: Check all mounting bolts and clamps for tightness. Ensure heat shields are securely fastened.
• Exhaust Leaks: Inspect all joints and connections. Loose clamps or damaged gaskets can cause leaks. Re-tighten or replace as necessary.
• Discoloration: While the heat shields are designed to be blue-proof, extreme engine tuning or prolonged idling can sometimes affect the finish. Ensure proper engine tuning.

For persistent issues, consult a qualified motorcycle mechanic or contact Vance & Hines customer support.

Specifications

Warranty Information

Vance & Hines products are typically covered by a manufacturer's warranty against defects in materials and workmanship. For specific warranty terms, conditions, and duration, please refer to the warranty documentation included with your purchase or visit the official Vance & Hines website. Keep your proof of purchase for warranty claims.

Support

For technical assistance, parts inquiries, or further support regarding your Vance & Hines Big Radius exhaust system, please contact Vance & Hines customer service directly. Contact information can typically be found on their official website or in the packaging materials.