Vance & Hines Power Duals Exhaust System Instruction Manual

1. Product Overview

The Vance & Hines Power Duals Exhaust System, Model 46871, is designed to enhance the performance of Harley-Davidson touring models. This system features a hidden power chamber crossover, which significantly improves the motorcycle's stock performance by increasing horsepower and torque. Additionally, it is engineered to reduce heat on the left side of the bike, providing a more comfortable experience for passengers and protecting critical engine components and side covers from heat damage.

Image: Vance & Hines Power Duals Exhaust System, Model 46871, showcasing the black finish and contoured heat shields.

2. Key Features

• Contoured Heat Shields: Unique heat shields elegantly conceal the power chamber crossover, enhancing aesthetics while improving performance.
• Reduced Exhaust Temperatures: Helps reduce exhaust temperatures by up to 250 degrees Fahrenheit, contributing to rider and passenger comfort.
• Full-Coverage Heat Shields: Provides comprehensive heat protection for the exhaust system.
• Dual Oxygen Sensor Ports: Includes both 18mm and 12mm oxygen sensor ports for compatibility with various fuel management systems.
• Performance Enhancement: Designed to significantly improve the motorcycle's stock horsepower and torque.

3. Installation and Setup

Installation of the Vance & Hines Power Duals Exhaust System requires careful attention to detail. It is recommended that installation be performed by a qualified technician. Ensure all components are present before beginning the installation process.

3.1. Required Components (Sold Separately)

• Mufflers: This system consists of headpipes only. Compatible Vance & Hines slip-on mufflers designed for touring models are required for a complete exhaust system.
• Fuel Management System: For EFI-equipped motorcycles, a fuel management system such as Vance & Hines Fuelpak or Fuelpak FP3 is strongly recommended to optimize fuel delivery and ensure proper engine tuning after exhaust installation.
• Tri-Glide Adapter Kit: For Tri-Glide models, a specific adapter kit (e.g., 974-997 chrome or 974-998 black) is required and sold separately.
• Oxygen Sensors: While the system includes ports for 12mm and 18mm O2 sensors, the sensors themselves are typically sold separately or are part of your motorcycle's existing system.

3.2. General Installation Steps (Consult detailed instructions provided with the product)

1. Safely secure the motorcycle on a stand.
2. Remove the existing exhaust system, carefully disconnecting oxygen sensors and mounting hardware.
3. Install the new Vance & Hines Power Duals headpipes, ensuring proper alignment and fitment. Do not fully tighten hardware until all components are in place.
4. Install the chosen slip-on mufflers onto the Power Duals headpipes.
5. Connect oxygen sensors to the appropriate 12mm or 18mm ports.
6. For Tri-Glide models, install the required adapter kit.
7. Once all components are in place, tighten all mounting hardware to the manufacturer's specified torque settings.
8. If using a fuel management system, install and configure it according to its specific instructions.

4. Operation Considerations

After installation, the Vance & Hines Power Duals system will alter the exhaust flow and engine characteristics. It is crucial to ensure proper engine tuning, especially on EFI models, to prevent potential damage and achieve optimal performance. The recommended fuel management system (Fuelpak or Fuelpak FP3) will help maintain correct air/fuel ratios, maximizing the benefits of the exhaust system, such as increased horsepower and torque, and ensuring smooth engine operation.

The system's design also contributes to a cooler riding experience by significantly reducing heat on the left side of the motorcycle, which is particularly beneficial for passengers.

5. Maintenance

Regular maintenance of your Vance & Hines Power Duals exhaust system will ensure its longevity and continued performance.

• Regular Inspection: Periodically check all mounting bolts and clamps for tightness. Vibrations from motorcycle operation can loosen fasteners over time.
• Cleaning: Clean the exhaust system regularly with a mild soap and water solution. Avoid abrasive cleaners or harsh chemicals that can damage the finish. For black finishes, use products specifically designed for matte or black exhaust systems.
• Heat Shield Care: Inspect heat shields for any signs of damage or discoloration. Ensure they remain securely attached.
• Oxygen Sensors: If you experience performance issues, inspect oxygen sensors for carbon buildup or damage. Consult your motorcycle's service manual for sensor cleaning or replacement procedures.
• Gaskets and Seals: Check exhaust gaskets and seals for leaks. Replace them if any signs of wear or leakage are observed.

6. Troubleshooting

This section addresses common issues that may arise with your exhaust system.

• Exhaust Leaks: If you hear a popping sound or feel exhaust gases escaping, check all connections and gaskets. Ensure all clamps and bolts are tightened to specification. Replace any damaged gaskets.
• Performance Issues (e.g., backfiring, poor acceleration): These symptoms often indicate an issue with fuel management. Ensure your fuel management system (if installed) is correctly configured for the new exhaust. Consult a professional for engine tuning if necessary.
• Discoloration of Pipes: While some bluing or discoloration is normal for exhaust systems due to high temperatures, excessive or uneven discoloration might indicate an overly lean fuel mixture. This reinforces the importance of proper fuel management.
• Rattling Noises: Check for loose heat shields or internal baffles. Ensure all mounting hardware is secure.

If you encounter persistent issues that cannot be resolved with these steps, it is advisable to consult a certified motorcycle mechanic or contact Vance & Hines customer support.

7. Technical Specifications

8. Warranty and Support

Vance & Hines products are manufactured to high standards. For specific warranty information regarding your Power Duals Exhaust System, please refer to the warranty card included with your product or visit the official Vance & Hines website. In case of technical questions, installation assistance, or warranty claims, please contact Vance & Hines customer support directly through their official channels.

Always retain your proof of purchase for warranty purposes.