VANCE HINES 2004-2013 Harley-Davidson Sportster Mini Grenades Instruction Manual
- June 15, 2024
- VANCE HINES
Table of Contents
VANCE HINES 2004-2013 Harley-Davidson Sportster Mini Grenades
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 the exhaust system for missing or damaged parts and if you need any assistance please contact our technical support line at 562-921-7461.
PARTS LIST
NO. PART NO. Description Qty.| | 8| A758HW|
Barrel Band Clamp| 2
---|---|---|---|---|---
1 D866FC Front Head Pipe 1| | 9| A270HW|
Hose Clamp| 6
2 D867FC Rear Head Pipe 1| | 10| A121HW|
18mm Copper Washer| 2
3 D876HP Front Heat Shield 1| | 11| A213HW|
18mm Plug-Zinc| 2
4 D877HP Rear Heat Shield 1| | 12| A139HW|
1/4-20 x 1/2 Flange Bolts| 4
5 D686RP Lower Muffler Can 1| | 13| A288HW|
Nylon Cable Tie| 1
6| D687RP| Upper Muffler Can| 1| |
7| 1123-P| Mounting Bracket| 1| |
HARDWARE
TOOLS REQUIRED
STOCK EXHAUST SYSTEM REMOVAL
- If equipped, find and unplug the O2 sensor wires from the wiring harness.
- Feed the end of the wires through the frame so they are free from the motorcycle. Pay attention to the wire routing for re-installation.
- Loosen the heat shield clamps on both the front and rear head pipes. This allows for easier access to the head pipe mounting nuts.
- Remove the two head pipe mounting nuts from each flange, located at the cylinder head.
- Remove the clamp bolts that mount the rear head pipe to the belt drive cover bracket.
- Remove the two bolts from each muffler body where they attach to the mounting bar. Carefully remove the exhaust pipes from the motorcycle and set them aside.
- Remove the belt drive cover and take the bracket off the rear cover bolt, this bracket will not be reused.
- Remove the brake rod at the rear eyepatch Remove the right-side rider foot controls.
- Remove the three mounting bolts and washers attached to the exhaust mounting bar and save the hardware for reuse.
- Carefully remove the O2 sensors from the stock head pipes and save them for reuse with the new system.
- Carefully remove exhaust port flanges and circlips from the stock exhaust system using snap ring pliers. Replace bent or damaged circlips.
- Check the exhaust port gasket condition and replace it if necessary. Harley-Davidson part number: 65324-83B.
VANCE & HINES EXHAUST INSTALLATION
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Install the supplied mounting bracket, 1123-P, using the stock washers and bolts. Hand tighten only at this time.
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Using a levelling tool, level the mounting bracket to the bottom tube of the frame. See Figure 1. NOTE: The mounting bracket may need adjustment to ensure the head pipes and mufflers are parallel.
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Torque the mounting bracket bolts to 30-33 Ft./Lbs.
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Reinstall the drive belt cover. Torque the 3/8” bolt to 30-33 FT./Lbs. and the 1/4” bolts to 80- 120 In./Lbs.
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Re-install at brake rod eyelet using removable thread locking compound (Loctite ® 243 recommended). Torque to 120-180 In/Lbs. Re-install foot controls with A171HW-P spacer.
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Remove head pipes and heat shields from their protective packaging.
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Place each heat shield on a non-abrasive surface such as a blanket or carpet.
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Using a pencil, lightly mark outside edge of each heat shield to show the location of mounting clips where hose clamps will loop through.
NOTE: Pencil marks can be erased if care is taken not to harm the coating. -
Lay the head pipes into heat shields and loosely install hose clamps by feeding the tail end of the hose clamps into heat shield clips. Take note of the screw head direction. Figure 2. Screw heads should be accessible when the system is installed on a motorcycle for adjustment purposes.
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Apply a small amount of anti-seize compound to the threads of the O2 sensors and install them into the new head pipe.
NOTE: 2007 – 2013 models or models using 18mm wideband oxygen sensors install sensor directly into the head pipe. and models not using O2 sensors installed supplied 18mm plug and copper washer. -
Install the exhaust port flanges and circlip from the stock system onto the new head pipes.
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Using stock flange nuts, carefully install the head pipes into exhaust ports. Do not tighten the nuts at this time.
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Slide the band clamps onto each muffler. Make sure that the nuts on the clamps are accessible when installed on the bike. See Figure 2.
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Install and slide the mufflers on one at this time. The muffler with the Vance & Hines logo must be installed on the upper rear head pipe.
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Hand-tighten the muffler bodies to the bracket using the four 1/4-20 x 1/2 flange head bolts.
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Tighten the band clamps from the mufflers to the head pipes.
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Make sure to align the head pipes and mufflers then tighten the cylinder port exhaust flange nuts on front and rear cylinders. See Figure 3
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Tighten the muffler mounting bolts.
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Reconnect O2 sensors to the wire harness.
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Be sure to tighten all hardware before starting the motorcycle.
FIGURE 1
FIGURE 2
FIGURE 3
Emissions Notice
In California, 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 90 days. This warranty does not cover discolouration 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 labour 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.
13861 ROSECRANS AVENUE / SANTA FE SPRINGS, CA 90670 SALES:
562-921-5388
TECHNICAL: 562-926-5291
FAX: 562-802-0110