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2007 Yamaha V-Star 1300 Classic Straights Installation Instructions

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Filed Under (Yamaha) by admin on 08-11-2010

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Stock Exhaust System Removal 1. Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove bolts that are holding pipes at rear mounting bracket. 3. Loosen clamps at mufflers. 4. Remove mufflers. 5. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 6. Remove rear exhaust pipe assembly. 7. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 8. Remove front exhaust pipe assembly. 9. Remove exhaust-mounting bracket from frame. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system. 1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. 3. Install Front exhaust header pipe, taking care to not scratch chrome surfaces on pipe, engine or motorcycle — use masking tape as needed. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install Nut strip into each slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 8. Install Nut strip into each slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration. 15. Before starting bike wipe off any fingerprints and grease off pipes. Start bike and check for any exhaust leaks. NOTE: To achieve optimum performance from your Hard-Krome exhaust system we suggest installing the Dynojet jet kit for carbureted models

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Harley davidson American Classic Straights on a 1988-2001 VLX 600 Shadow Installation Instructions

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Filed Under (Harley Davidson) by admin on 01-03-2012

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Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove bolts that are holding pipes at rear mounting bracket. 3. Loosen clamps at mufflers. 4. Remove mufflers. 5. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 6. Remove rear exhaust pipe assembly. 7. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 8. Remove front exhaust pipe assembly. 9. Remove exhaust-mounting bracket from frame. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system.
1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. (See Illustration) 3. Install Front exhaust header pipe, taking care to not scratch chrome surfaces on pipe, engine or motorcycle — use masking tape as needed. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install nut strip into slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the rear cylinder head — DO NOT TIGHTEN NUTS! 8. Install nut strip into slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration. 15. Before starting bike wipe off any fingerprints and grease off pipes. Start bike and check for any exhaust leaks.

1999-2007 Yamaha V Star 1100 3" Res-Tec Installation Instructions

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Filed Under (Yamaha) by admin on 08-11-2010

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Stock Exhaust System Removal 1. Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove O2 sensors from each muffler and cover with supplied cap plug. 3. Loosen clamps at mufflers. 4. Remove bolts that are holding mufflers at rear mounting bracket. 5. Remove mufflers. 6. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 7. Remove rear pipe assembly. 8. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 9. Remove front pipe assembly. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system. 1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. (See Illustration) 3. Install Front exhaust header pipe, taking care to not scratch chrome surfaces on pipe, engine or motorcycle — use masking tape as needed. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install 3/8-16 Square nut into each slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 8. Install 3/8-16 Square nut into each slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration. 15. Before starting bike wipe off any fingerprints and grease off pipes. Start bike and check for any exhaust leaks

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Yamaha Stratoliner 2006 3" Big Straights REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 02-01-2012

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1. Remove right side Foot peg assembly or Floorboard. (Whichever is applicable to your model.) 2. Remove bolts that are holding muffler at rear mounting bracket. 3. Remove Cables from exhaust valve. 4. Remove O2 Sensor from pipe. 5. Remove the two nuts that secure the rear exhaust header pipe to the rear cylinder head. 6. Remove the two nuts that secure the front exhaust header pipe to the front cylinder head. 7. Remove complete pipe assembly. Hard-Krome Exhaust System Installation NOTE: Take care when fitting this Hard-Krome aftermarket exhaust system on your motorcycle. It has been designed to replace a STOCK exhaust system on a motorcycle with its engine, frame and other components in their STOCK design, configuration and location. WARNING : Re-check and re-tighten ALL fasteners and supports after 50 miles, then re-check and tighten as necessary on a periodic basis to ensure proper operation and performance. NOTE: All fasteners should be loose during initial installation to ensure proper fit and location of the new exhaust system. 1. Install new exhaust gaskets. 2. Install mounting bracket using Bolts with flat & lock washers. (See Illustration) 3. Install O2 Sensor onto front pipe and install front pipe onto front cylinder, taking care to not scratch chrome surfaces on pipe, engine or motorcycle. 4. Install the two nuts to secure the flange that holds the exhaust header pipe to the front cylinder head — DO NOT TIGHTEN NUTS! 5. Install 3/8-16 Square nut into each slotted bracket of front pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 6. Carefully install rear pipe onto rear cylinder. 7. Install the two nuts to secure the flange that holds the exhaust header pipe to the rear cylinder head — (Remove chrome plastic valve cover to access top nut) — DO NOT TIGHTEN NUTS! 8. Install 3/8-16 Square nut into each slotted bracket of rear pipe and start the 3/8-16×3/4″ Bolt with flat & lock washer through backside of mounting bracket. — DO NOT TIGHTEN BOLTS! 9. Tighten the two bolts that secure the rear exhaust header pipe flange. 10. Tighten the two bolts that secure the front exhaust header pipe flange. 11. Tighten front pipe bolts at mounting bracket. 12. Tighten rear pipe bolts at mounting bracket. 13. Reinstall foot peg assembly or floorboard. 14. If applicable to your model install foot peg relocating brackets and foot pegs as shown in illustration.

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YAMAHA VIRAGO 700/ 1100 2 into 2 EXHAUST SYSTEM REMOVAL AND INSTALLATION MANUAL

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Filed Under (Yamaha) by admin on 20-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the slip joint clamp on the front and rear head pipe, which are located at the muffler box. 2. Remove the two nuts that hold the front head pipe to the engine. Slip the head pipe out of the muffler box and set it aside. Note: Do not remove the rear head pipe, it has been incorporated in the design of the new exhaust system. 3. Remove the muffler box mounting bolt located in front of the passenger foot rest on the left side. 4. Remove two bolts from the right passenger foot rest assembly and set the foot rest aside. 5. Slide the muffler box off of the rear head pipe and set it aside. 6. Replace the muffler box mounting bolt (from step #3) using the washer and nut (supplied) on the back side. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Attach the mounting bar to the motorcycle frame behind the right passenger foot rest. Align the two holes in the largest bracket on the mounting bar with the two holes on the frame, be sure the bend in the mounting bar is pointing to the center of the motorcycle. 2. Install the round steel spacer (supplied) to the rear most hole in the bracket. 3. Attach the foot rest using the two 8mm x 1.25 x 25mm bolts (supplied). 4. Slide the new exhaust flange (supplied) onto the front head pipe. 5. Install the two heat shields to the front head pipe using the four hose clamps (supplied). Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Place the heat shields onto the front head pipe. Note: Be sure the bend in the heat shield matches the bend in the head pipe exactly. Wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 6. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 7. Slide a chrome pinch clamp (supplied) onto the expanded end of the new rear head pipe. Install a 3/8″ x 1″ bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Repeat this step on the inlet end of each muffler using the two muffler clamps with 5/16″ x 1 1/4″ bolts (hardware supplied) but leave the clamp loose at this time. 8. Slip the new rear head pipe with the heat shield attached, over the stock rear pipe and gasket, but leave the clamp loose at this time. 9. Install the front head pipe, with the heat shield attached and stock gasket in place, to the front cylinder using the stock nuts, leave them loose at this time

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Kawasaki Vulcan 400/ 800 Preload Improvement Kit Installation Instructions

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Filed Under (Kawasaki) by admin on 01-12-2010

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1. Begin by removing both side compartment covers. The RH compartment cover requires the use of the ignition key for removal; the LH compartment cover is secured by a large Phillips screw. Once you’ve removed the LH cover, place the Phillips screw back into the hole in the frame (so you don’t misplace it) and set both covers aside. In many applications, you must remove the upper exhaust pipe (from the rear cylinder), and loosen the other pipe, to remove the inner parts of the RH side compartment cover (see below). Before attempting step #2 below, try step #3 first… depending on the brand of exhaust pipes you have, you may be able to avoid removal in step #2, if you are successful with step #3 first. Some brands of exhaust pipes provide access to the fasteners securing the RH side covers, eliminating the requirement to remove pipes for rear suspension access. 2. Remove the rear cylinder’s exhaust pipe. To do so, remove the two Allen nuts on the exhaust header, where it attaches to the engine, using an 8mm Allen wrench. Most often, this goes much more smoothly if you first spray the inside of the allen nut with a penetrating lubricant like WD-40. Remove the black acorn nut from the discharge end of the exhaust pipe (under the upper exhaust pipe, near the discharge end of the pipe) using a 12mm open-end wrench or socket. You’ll find a black metal spacer, through which the bolt goes, that is pressed through the rubber grommet. To avoid the potential of having it fall out unnoticed, remove it and place it aside with the nut. Remove the black bolt from the pipe just aft (to the rear) of where the pipe enlarges and above the pipe. This is actually a bracket that holds the two pipes together at a joint. Loosen the bolt using a 12mm socket, then slide it back onto the pipe you’re removing. Once you have the pipe off of the bike, the clamp will be loose. Be sure to keep it with the pipe, along with the rest of the removed parts. Loosen the pipe from the front cylinder BEFORE trying to remove the pipe from the rear cylinder. By loosening the header nuts on the pipe from the front cylinder, and removing the two black Allen bolts (6mm Allen wrench) under the forward pipe that attach it to the frame, you will be able to remove the rear pipe. There are more spacers in grommets where the 6mm Allen bolts secure the lower pipe to the frame (like those used in the rearmost connection o

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Harley-Davidson V-Rod Destroyer Indy Series Exhaust REMOVAL AND INSTALLATION

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Filed Under (Harley Davidson) by admin on 24-10-2010

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STOCK EXHAUST SYSTEM REMOVAL (DESTROYER) 1. Remove both collector bolts. 2. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 3. If the Racepak is installed, remove both O2 and EGT sensors from the front and rear head pipes. 4. Carefully remove complete exhaust from the motorcycle. STOCK EXHAUST SYSTEM REMOVAL (V-ROD) 5. Loosen clamp bolt at front of the collector using a 13mm socket. 6. Remove muffler bracket bolt using a 13mm wrench. 7. Carefully remove muffler and collector assembly from motorcycle. 8. Remove nuts from both front and rear exhaust cylinder head flanges using a 13mm socket. 9. Carefully remove head pipes from motorcycle. 10. Remove the stock exhaust flanges and circlips from both the front and rear head pipes. If the circlips are bent or twisted they should be replaced, Harley-Davidson part number #65045-01 We also recommend replacing the stock exhaust gaskets, Harley-Davidson part number #65109-01 INDY SERIES EXHAUST SYSTEM INSTALLATION 1. Identify front head pipe #7-8002. Install the stock flange and circlip. Install the exhaust gasket and front header pipe, leaving the flange nuts hand tight. 2. Repeat the above step for the rear head pipe #7-8006. 3. Slip the megaphone/collector assembly onto the head pipes, secure with the four springs supplied using the spring puller tool. 4. Rotate the exhaust so there is adequate clearance in all places. 5. Tighten the cylinder head flange nuts for both the front and rear head pipes. 6. Tighten both the EGT and O2 plugs on the front and rear head pipes. 7. Clean all fingerprints from the exhaust using a contact cleaner (or other non flammable cleaner). Fingerprints will leave stains on the pipe once the motorcycle is started. 8. You are now ready to start the motorcycle.

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SUZUKI M109 1800 cc EXHAUST SYSTEM INSTALLATION MANUAL

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Filed Under (Suzuki) by admin on 10-11-2010

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1. Remove the seat and right side fairing cover (with M109 insignia), behind the fuel tank. To remove the fairing, release the plastic peg on top by pushing the center inward and pulling the fairing upwards until the peg releases, remove the M6 button head bolt at the bottom of the fairing. Pull the fairing outward from the rear and upward near the plastic peg to release it. Once it is free from all plastic pegs pull it forward to release it from the bottom of the fuel tank. 2. Remove the right side cover above the exhaust-mounting bracket secured by one M6 button head bolt, retain bolt for later. Remove the chrome steel cover above the exhaust secured by two remaining bolts, (this chrome piece will no longer be used.) Remove the large left rear rubber grommet and flanged steel collar from this chrome piece, to do this press the steel collar out of the rubber grommet first, once the collar is removed push the rubber grommet out of the wire loop on the chrome piece, set aside for later use. 3. Locate the exhaust valve actuator solenoid and harness and disconnect the black 3-prong electrical connector and white 2-prong electrical connector. 4. Remove the socket head bolts securing exhaust flanges to cylinder heads, set these fasteners aside for later use in reassembly. Support the weight of the exhaust system and remove the 2, 8 mm bolts and one 8 mm nut securing the exhaust mounting bracket and exhaust assembly. Keep these fasteners for use later. Remove the stock exhaust system as one complete unit; this includes the stock exhaust bracket, headpipes and muffler, exhaust valve solenoid and cables. 5. The exhaust valve actuator solenoid must now be removed from the stock exhaust-mounting bracket. To perform this, loosen the two nuts securing each cable to the exhaust valve cable-mounting tab, Position A in Figure 1. Make enough slack in the cables so that the ends of the cables’ threaded sheath may be disengaged from the end of the mounting tab. Now remove the two M6 hex head bolts securing the solenoid to the stock exhaust bracket. The stock exhaust mounting bracket, headpipes and muffler and exhaust valve solenoid cables will not be used anymore with the your new Cobra Exhaust System. 6. Remove the dust cover from the solenoid to expose the rotating cam and cables. DO NOT TRY TO ROTATE THE CAM RELATIVE TO THE ACTUATOR SELENOID TO REMOVE THE CABLES; DOING SO MAY DAMAGE THE INTERNAL COMPONENTS OF THE SOLENOID. To remove the cables from the cam, use the slack in the cables obtained in Step 5 to disengage the cable barrels from the cam, see Figure 1. THE DUST COVER WILL NOT BE REINSTALLED. 7. Now prepare the exhaust valve actuator solenoid for reuse. SECURELY HOLD THE CAM TO PREVENT IT FROM ROTATING IN THE SOLENOID. WHILE PREVENTING THE CAM FROM ROTATING, remove the 10 – 32 flange bolt securing it, see Figure 2. Replace the cam with the Cobra supplied cam, BE SURE TO PREVENT THE CAM FROM ROTATING WHEN REINSTALLING THE BOLT, OTHERWISE DAMAGE MAY OCCUR TO THE SOLENOID , see Figure 3. Torque to factory specifications.

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HARLEY DAVIDSON DYNA LongShot Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Remove the two mounting nuts from each head pipe, located at the cylinder head. 3. Remove both front and rear head pipe clamp bolts. 4. Remove the entire exhaust system and set it aside. 5. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them with new circlips. 6. Remove the rear head pipe clamp bracket from the transmission cover. Save the bolts, two will be reused. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Locate the muffler mounting bracket (stamped 239). Mount the bracket to the engine case, to the rear of the transmission cover using the two stock bolts. Refer to figure 1. Tighten the bolts at this time. Install the mounting bar (supplied) to the transmission housing using the stock hardware. Refer to figure 1 . Note: The mounting bracket should mount flatagainst the transmission housing. Some motorcycles use a stud to mount the stock rear head pipe clamp, be sure to remove the stud from the transmission housing and replace it when mounting the bracket, this will insure that the bracket is flat against the housing. 2. Locate the muffler clamp bracket (stamped 240). Install the bracket to the outside of bracket 239, using the 5/16″x 1 1/4″ bolt and 5/16″ flat washer (supplied). Refer to figure 1. Leave the bracket loose, it will be adjusted later. 3. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of both heat shields. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 4. Install the circlips and flanges from the stock system onto both the new head pipes. 5. Slide the new pipe clamp (supplied) onto the muffler end of the front head pipe. Position the clamp in the approximate mounting location on the pipe. 6. Place the front head pipe into the heat shield, wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the rear head pipe.

HARLEY DAVIDSON SOFTAIL 2 into 1 Pro Pipe Exhaust System Installation Manual

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Filed Under (Harley Davidson) by admin on 22-12-2010

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REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the heat shield clamps on both front and rear exhaust pipes. 2. Loosen the crossover pipe clamp, located between the front and rear head pipes. 3. Remove the two mounting nuts from each head pipe, located at the cylinder head. 4. Remove the two nuts from the back side of each muffler. 5. Remove the entire exhaust system and set it aside. 6. Carefully remove the flanges and circlips from the stock exhaust system using snapring pliers. Note: If circlips look bent or twisted replace them. 7. Remove the two bolts that hold the front muffler mounting bar to the frame. Note: FLSTN, FLSTF models require the removal of the stock exhaust system mounting bar. For removal: Remove the right passenger foot peg bolt. Position the motorcycle on it’s side stand with a floor jack under the swing arm pivot bolt on the right hand side. Raise the jack just enough to take the weight off the pivot bolt and remove the bolt and stock mounting bar. Replace the pivot bolt and torque it between 120 -150 ft. lbs. 8. Reinstall the foot peg bolt using the 1/2″ x 3″ bolt and spacer tube (both supplied). Tighten the bolt making sure the foot peg folds in the proper direction. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM Note: For easier installation on models with floorboards, it will be necessary to loosen the right side floorboard. 1. Check the stock exhaust gaskets to be sure they’re in good shape. If you have any doubts as to their condition, replace them. 2. Unscrew all of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose clamp into the clips on the inside of each heat shield. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the motorcycle. 3. Install the circlips and flanges from the stock system onto both new head pipes. 4. Install the header using the stock nuts, but leave them loose at this time. 5. Install the new mounting bracket to the frame below the right rear foot peg, using the two 3/8″x 3/4″ flange bolts (supplied), and tighten. 6. Slide the dog bone shaped nut plate under the bracket that is welded to the backside of the muffler.

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