Home Page - Vance & HinesCALIFORNIA CUSTOMER - Vance & Hines
Home Page - Vance & Hines
Instruction Manual for VANCE HINES models including: 27325 Stainless 2 1 Exhaust System, 27325, Stainless 2 1 Exhaust System, 2 1 Exhaust System, Exhaust System, System
File Info : application/pdf, 7 Pages, 1.95MB
DocumentDocumentINSTALLATION INSTRUCTIONS: HARLEY-DAVIDSON DYNA 2010-2017 STAINLESS 2-1 PART# 27325 Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your Vance & Hines exhaust is designed and crafted for performance, quality, and style. Please follow the instructions below, check exhaust system for 7 missing or damaged p6arts and if you need any 5assistance please contac4t our technical support li3ne (562) 921-7461. 2 1101 1 3 2 PARTS LIST NO. Part No. Description 1 D374RB-S/D337RP-S Muffler can assembly 2 D1122FB/D1322FP Front head pipe assembly 3 D1123FB/D1323FP Rear head pipe assembly 4 A240HW 5/16-18 X 5/8" FHS 5 A195HW Dogbone nut plate 7 6 A644ST 7 A115SP 6 18-12mm O2 adap5tor Dirt Sport Spring 8 A260SP Spring puller Qty. 1 1 1 2 1 2 2 1 NO. Part No. 9 A283HW 10 1169-P 11 A527HW-P 12 A107HW 13 A345HW 14 4 71001 Description Qty. 3/8-16 low profile SHCS 2 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF VA DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, UNLES UNLESS OTHERWISE SPECIFIED NAME Mount bracket 1 INTERPRET DIMENSIONS AND TOLERANCES PER ANSI Y14.5M CAD DIMENSIONS ARE INCHES J. ARCEO TOLERANCES ARE: DRAWN Floor board spacer 1 THIRD ANGLE PROJECTION FRACTIONAL: ANGULAR: X.X X.XX 1/16" 2 0.030" 0.015" J. ARCEO CHECKED S. GUTIERREZ X.XXX 0.010" APPROVED 5/16" SAEMATfElRaIALt washer 3 M. BERMUDEZ DATE 7/2/2018 7/2/2018 7/20/2018 SANT BR www.v PROJECT 9/7/2018 TITLE SEE INDIV. DWGS 5/16-18 X 1 FINISH1/2" bolt 3 SIZE PA B BRUSHED 6IN O2 ext3ension lead 12 WT. 10.7 Page 1 of 7 27325IN HARDWARE 1156 8 1145 7 4 1123 5 6 1121 14 190 9 TOOLS REQUIRED Flat blade Screwdriver Combination Wrench: 116/42m",m7/8" or 22mm & 5 Allen Wrenches: 3/16", 1/4", 3/8" 5/16" Nut Driver THE INFORMATION CONTAINED IN THIS DRAWING IS DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR A UNLESS OTHERWISE SPECIFIED NAM INTERPRET DIMENSIONS AND TOLERANCES PER ANSI Y14.5M THIRD ANGLE PROJECTION CAD DIMENSIONS ARE INCHES J. ARC TOLERANCES ARE: FRACTIONAL: 1/16" ANGULAR: 2 X.X 0.030" X.XX 0.015" DRAWN J. ARC CHECKED S. GUTIE X.XXX 0.010" APPROVED M. BERM MATERIAL SEE INDIV. DWGS 3/8" Ratchet, extenFsINIiSoH ns 4 19//21"6"&D1e9empmSoScokcektet3s BRUSHED Snap ring Pliers Page 2 of 7 27325IN STOCK EXHAUST SYSTEM REMOVAL 1. For O2 sensor equipped models (10-17), remove seat to gain access to rear oxygen sensor connector. Unplug sensor and feed end of wire through frame to free it from motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. For 2010 to 2011 models, remove two bolts holding rectifier onto front of frame (near front tire). Open plastic cover to gain access to front oxygen sensor connector. Unplug sensor from harness and feed end of wire through to free it from motorcycle. For 2012 to later models, the connector is located under the rectifier at the front of the motorcycle. 3. Loosen the heat shield clamps on both the front and the rear head pipes. 4. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder head. 5. If equipped, remove the front head pipe clamp carriage bolt. 6. Remove the bolt that attaches the mufflers to the frame mounting bar. 7. Remove the complete exhaust system and set aside (assistance may be required). 8. Remove the stock mounting bar and the studs in the transmission cover. 9. Position the muffler support bracket over mounting location to determine which bolts to remove (Figure 1). Install removed bolt in the top hole left vacant by the new bracket. 10. Carefully remove the flanges and circlips from the stock exhaust system using snap ring pliers. NOTE: Replace bent or damaged circlips. (Recommended replacement exhaust port gaskets, HD #65324-83B). 11. Carefully remove stock oxygen sensors. They will be re-used on the new system. VANCE & HINES EXHAUST INSTALLATION 1. Attach the muffler support bracket to transmission and tighten to 12-15ft/lb. Torque using three 5/16" x 1 1/2" hex head bolts and washers (items 13 & 15) (Figure 1). 2. Install the mid control spacer (item 12) on motorcycles equipped with mid controls using 2x 3/816 low profile SHCS (item 10) (Figure 2). 3. Remove head pipes from protective packaging. Apply a small amount of anti-seize compound to the threads of the oxygen sensors and install them into the new head pipe. NOTE: For 2010 to 2011 models or models using 18mm wideband oxygen sensors, install sensor directly into head pipe. For 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.) For all models not using oxygen sensors, install 18mm plug with copper crush washer. 4. Install exhaust port flanges and circlips (from stock system) onto head pipes. 5. Using stock flange nuts, carefully install head pipes into exhaust ports, starting with the rear cylinder. Assistance may be required. NOTE: Do not tighten at this time. 6. Install muffler assembly onto head pipes. Attach muffler assembly to installed bracket and secure with 5/16-18 flange bolts & dog bone nut plate (supplied). 7. Install springs using supplied spring puller. There should be about a 2" gap between the spring tabs (Figure 3). 8. Tighten exhaust port flange nuts and 5/16" flange head bolts at the bracket. Page 3 of 7 27325IN VANCE & HINES EXHAUST INSTALLATION CONTINUED 9. 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. 10. For 2010 to 2011 models, put the toothed edge of the wiring holder into the slot in frame. Re-install rectifier so that it fits under tooth of wiring holder, keeping it in place in the frame. Tighten both the bolts. 11. Install a new cable tie (supplied) to hold wires in original location. 12. Feed connector for rear oxygen sensor through frame and into the under seat compartment. Plug sensor into stock wiring connector. For 2010 to 2011 models, use supplied O2 extension lead (item 16). 13. Reinstall the seat. 14. Check for adequate clearance between all exhaust system components and motorcycle accessories prone to heat damage. NOTE: On some mid control models, rear brake pedal height may need to be adjusted to achieve clearance to rear head pipe when brake is engaged. Use the following steps to adjust brake pedal height. 1. Remove muffler and front head pipe. 2. Remove bolts securing the brake pedal bracket to the frame. 3. Remove pin and disengage brake rod from brake pedal. 4. Loosen the brake rod jam nut next to the master cylinder. 5. Rotate the brake rod counter clockwise lengthening the brake rod 3-5 turns. 6. Tighten the jam nut securely. 7. If necessary, ensure the drain hole in the rubber boot is positioned to the bottom. 8. Re-install brake pedal bracket to the frame using spacer and low profile allen screws. 9. Re-install front head pipe and muffler then check brake pedal clearance. 10. If necessary, repeat adjustment until brake pedal does not contact rear head pipe when the brake is applied. · Caution: When adjusting brake control rod, never allow more than six threads to be exposed between control rod and jam nut. If six (6) threads are visible past the jam nut, there is insufficient break rod thread engagement into the master cylinder push rod. This could cause the brake rod to separate from the push rod, making the rear brake inoperative. 15. Be sure to tighten all hardware before starting your motorcycle. Page 4 of 7 27325IN FIGURE 1 FIGURE 2 Page 5 of 7 27325IN FIGURE 3 2.0" EXHAUST CARE (STAINLESS) 1. When installing a new set of stainless pipes, make sure your hands are clean and free of oil. After installation, thoroughly clean pipes with a soft cloth and cleaning solvent that will leave no residue (glass cleaner, alcohol, acetone, etc...) before starting the motorcycle. 2. It is considered normal for stainless steel exhaust systems to discolor due to heat. 3. High performance engine tuning utilizing a dyno will likely result in severe discoloration. 4. Avoid long periods of idling as this can cause discoloration. Intake leaks can cause the engine to run lean and overheat and this could lead to discoloration. 5. 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. EXHAUST CARE (BLACK) 1. When installing a new set of black pipes, make sure your hands are clean and free of oil. After installation, throroughly clean pipes with warm soapy water and a soft cloth. Dry with a clean towel to remove any residue before starting the motorcycle. Do NOT use anything abrasive to clean pipes. 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. Page 6 of 7 D914IN RevB 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. 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. Page 7 of 7 13861 ROSECRANS AVENUE / SANTA FE SPRINGS, CA 90670 SALES: (562) 921-5388 TECHNICAL: (562) 926-5291 FAX: (562) 802-0110