Home Page - Vance & HinesCALIFORNIA CUSTOMER - Vance & Hines
Installation Guide for VANCE HINES models including: 46081, 46081 PCX Big Radius 2 Into 2 Exhaust, PCX Big Radius 2 Into 2 Exhaust, Big Radius 2 Into 2 Exhaust, Radius 2 Into 2 Exhaust, 2 Into 2 Exhaust, 2 Exhaust
Vance & Hines PCX Big Radius 2-Into-2 Exhaust For Harley Dyna 2006-2009 - RevZilla
File Info : application/pdf, 4 Pages, 1.24MB
DocumentDocumentHARLEY-DAVIDSON® DYNA BIG RADIUS 2-2 BLACK INSTALLATION INSTRUCTIONS PART# 46081 MORE POWER : LESS NOISE STOCK EXHAUST SYSTEM REMOVAL TOOLS REQUIRED Congratulations, you have purchased the finest exhaust system for your motorcycle on the market. 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, 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. Flat blade screwdriver and #3 Phillips Head 5/16" Nutdriver Snapring pliers 1/2", 7/8",or 22mm Combination wrenches 3/16" & 1/4" Allen wrenches 3/8" Ratchet & extensions 1/2", 19mm Sockets 7/16 & Deep Sockets READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION 1. Remove seat to gain access to rear oxygen sensor connector. Unplug required. sensor and feed end of wire through frame so that it is free from 8. Remove stock mounting bar and the studs in the transmission cover. motorcycle. NOTE: Pay attention to wire routing for re-installation. 9. Remove left bolt below the transmission cover. Position mounting bracket 2. Remove two bolts holding rectifier onto front of frame (near front tire). Open plastic cover to gain access to front oxygen sensor connector. 1391-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. Unplug sensor from ahrness and feed end of wire through to free it from motocycle. 10. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. NOTE: Replace bent or damaged circlips. 3. Loosen heat shield clamps on both the front and rear head pipes. 11. Remove stock exhaust gaskets and replace them with the supplied 4. Remove front head pipe clamp bolt. exhaust gaskets. NOTE: Replacement gaskets #22899 or HD Screaming 5. Remove the bolt that attaches rear head pipe clamp to mounting bar. Eagle #17048-98 or equivalent 6. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder head. 12. Remove stock oxygen sensors and set them aside for they will be re-used on new system. 7. Remove the complete exhaust system and set aside. Assistance may be FIGURE 1 TRANSMISSION COVER INSTALL ALLEN BOLT REMOVED FROM LOWER HOLE INSTALL SPACER BETWEEN BRACKET AND MOTOR USE 5/16-18 x 2.0" HEX BOLT AND WASHER (SUPPLIED) FIGURE 2 BRACKET 391-P USE 5/16"-18 X 1-1/2" HEX BOLTS AND WASHERS (SUPPLIED) Page 1 of 4 REMOVE ALLEN BOLT PRIOR TO INSTALLING MOUNTING BRACKET Installing circlip Flange 46081IN FIGURE 3 Installing hose clamp FIGURE 4 FIGURE 5 Arrows indicate clamp screw head direction FIGURE 6 MORE POWER : LESS NOISE VANCE & HINES EXHAUST SYSTEM INSTALLATION Mark outside edge Installing nutplate Align gap between mufflers 1. Attach mounting bracket 1391-P to transmission and tighten to 12-15 Ft/Lb 8. Align pipes on motorcycle so that the gap between the two muffler bodies is torque. (Figure 1). NOTE: 2006 to 2007 models use three 5/16" x 1-1/2" hex consistent from front to rear and tighten exhaust port flange nuts (Figure 6). head bolts and washers. 2008 to 2009 models use three 5/16" x 1-1/2" hex 9. Tighten flange bolts securing muffler bodies to mount bracket 1391-P. head bolt, washers, 11/16" spacer between the bracket and transmission in 10. Using the #28 hose clamps install the muffler heat shields with the D308HC on top hole. the front head pipe and the D325HP-S on the rear. Take note of screw head 2. Remove head pipes from their protective packaging and install circlips and direction (Figure 4). NOTE: Do not tighten at this time. flanges from the stock system onto both new head pipes (Figure 2). 11. Adjust the heat shields to get the best alignment at the seam where they 3. Apply a small amount of anti-seize compound to the threads of the oxygen touch (Figure 6) and tighten all the hose clamps. sensors and install them into the new head pipe. 12. Feed wire for front oxygen sensor through frame and into plastic holder on NOTE: 2006 to 2009 models or models using 18mm wideband oxygen sensors frame. Plug sensor into stock wiring connector. Snap plastic holder closed to install sensor directly into head pipe. hold connector in place. 4. Remove heat shields from their protective packaging. Place each heat 13. Put toothed edge of wiring holder into slot in frame. Re-install rectifier so that shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip it fits under tooth of wiring holder, keeping it in place in frame. Tighten both pen, mark outside edge of each heat shield to show location of hose clamp bolts. mounting clips (Figure 3). 14. Feed connector for rear oxygen sensor through frame and into underseat 5. Lay head pipes (D448FP & D449FP) into head pipe heat shields (D535HP compartment. Plug sensor into stock wiring connector. & D538HP) respectively. Make sure alignment clip on head pipe fits inside 15. Re-install seat. heat shield. Loosely install #20 hose clamps by feeding tail end of clamp 16. Check for adequate clearance between all exhaust system components into heat shield clips (Figure 3). Take note of screw head direction (Figure 4). and motorcycle accessories prone to heat damage. Screw head should be accessible when system is installed on motorcycle for 17. Be sure to tighten all hardware before starting your motorcycle. adjustment purposes. NOTE: Do not tighten at this time. 18. After installation and before starting motorcycle, completely clean pipes 6. Using stock flange nuts, carefully install head pipes into exhaust ports, starting and mufflers with warm soapy water and a clean soft cloth that will not with the rear cylinder. Assistance may be required. NOTE: Do not tighten at leave a residue. NOTE: Any residue, oil, or fingerprints will stain the chrome this time. when the metal heats up. 7. Slide nutplates inside brackets that are welded to backside of each muffler body (Figure 5). While holding nutplates in place, attach muffler bodies to mounting bracket 1391-P using four 5/16"x 5/8" flange head bolts (supplied). Leave them loose at this time. EXHAUST CARE - HELPFUL HINTS TO AVOID DISCOLORATION OF EXHAUST SYSTEM 1. When installing a new set of coated pipes, make sure your hands are clean and free 3. Intake leaks can cause the engine to run lean and overheat, this could lead to of oil. After installation, thoroughly clean pipes with warm soapy water and a soft discoloration. cloth. Dry with clean towel to remove any residue (wax / polish, glass cleaner, alcohol, 4. Make sure there are no exhaust leaks at the junction of the exhaust pipes and cylinder ammonia, etc...) before starting the motorcycle. head. We recommend replacing gaskets if they are worn. 2. Avoid long periods of idling as this can cause discoloration. VANCE & HINES OPTIONAL ACCESSORIES Quiet Baffle #23081 FP4 #66047 FUELPAK 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. Page 2 of 4 46081IN HARLEY-DAVIDSON® DYNA BIG RADIUS 2-2 BLACK INSTALLATION INSTRUCTIONS PART# 46081 #28 Hose clamps x 4 PACKING LIST #20 Hose clamps x 5 Exhaust Gaskets x 2 MORE POWER : LESS NOISE ALL PARTS SHOWN ARE ACTUAL SIZE 5/16" x 5/8" Flange head bolts x 4 Nutplates x 2 5/16" x 1-1/2" Hex head bolts x 3 5/16" x 2.0" Hex head bolts x 1 5/16" Flat washers x 3 11/16" x 9/16" Spacer x 1 PARTS NOT SHOWN: 1391-P Bracket x 1 D448FP Front head pipe assy x 1 D449FP Rear head pipe assy x 1 D535HP Front heat shield x 1 D538HP Rear heat shield x 1 D322HP-S Front muffler heat shield x 1 D325HP-S Rear muffler heat shield x 1 WARRANTY 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 finishes. 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 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 4 46081IN FUEL MANAGEMENT MORE POWER : LESS NOISE Connect. Tune. Ride. From the team that brought you The Fuelpak FP3, the best-selling ECU tuner in the world for Harley-Davidson motorcycles, the Vance & Hines FP4 is the most intuitive tuning tool on the market, giving you the power to control your motorcycle's tune and offers the best-in-industry support from our FP4 technicians, all from your smartphone. Download and Flash Maps Live Data Viewing Autotune Feature for Map Customization Visit vanceandhines.com to learn more about FP4. Qualified Manufacturer Declared 49-state Federal Emissions Compliant Part. Emissions Notice: In California, in order to meet Air Resources Board emissions requirements, certain aftermarket part applications have been identified as replacements, and others have received ARB Executive Orders. All other emissions related aftermarket parts are for competition use only. A list of replacement parts and EO parts, and corresponding fitment is provided at vanceandhines.com/California. Warranty: All Vance & Hines products are warranted against defects in material and workmanship for a period of 90 days. This warranty does not cover discoloration or rust. This warranty shall be limited to the repair or replacement of the product, which may be proven defective under normal use. Vance & Hines will not warranty any system that has been abused, misused, improperly installed or modified. Dealers or distributors are not authorized to make dispositions binding upon Vance & Hines. Vance & Hines will not be responsible for any labor charges incurred in removing or replacing any system under warranty. A return authorization number and a copy of the original purchase invoice must accompany all returns. Parts returned without a return authorization may be refused. 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 46081IN