VANCE HINES 26367 PCX Big Radius 2 Into 2 Exhaust for Harley Sportster Instruction Manual

: June 15, 2024
: VANCE HINES

Table of Contents

INSTALLATION INSTRUCTIONS:
PARTS LIST
HARDWARE
STOCK EXHAUST SYSTEM REMOVAL
VANCE & HINES EXHAUST INSTALLATION
EXHAUST CARE (CHROME)
EXHAUST CARE (BLACK)
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

VANCE HINES 26367 PCX Big Radius 2 Into 2 Exhaust for Harley Sportster

INSTALLATION INSTRUCTIONS:

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 missing or damaged parts and if you need any assistance please contact our technical support line 562-921-7461.

PARTS LIST

NO.|

PART NO. CHR. /BLK.

| Description| QTY
---|---|---|---
1| 904-P| Mount Bracket| 1
2| D363FC| Rear Header| 1
3| D362FC| Front Header| 1
4| D363HC / D343HP| Rear Heat Shield| 1
5| D362HC / D342HP| Front Heat Shield| 1
6| A195HW| Dog Bone Nut Plate| 2
7| A270HW| .81-1.75 IN Hose Clamp| 3
8| A272HW| 1.31-2.25 IN Hose Clamp| 4
9| A240HW| 5/16-18 x 5/8 Hex Bolt| 4
10| A644ST| O2 Adaptor| 2

HARDWARE

Flat blade screwdriver
5/16” Nut driver
9/16”, 1/2”, 3/4” & 14mm Combination Wrenches
3/16” & 5/16” Allen wrench
Snaring Pliers
Flub. Torque Wrench
3/8” Ratchet & Extension
1/2” & 9/16” Sockets
1/2” Deep sockets
3/16” & 5/16” Allen Sockets

STOCK EXHAUST SYSTEM REMOVAL

NOTE: These instructions are written for late model motorcycles equipped with O2 sensors. If you are installing these pipes on a bike which is not equipped with O2 sensors, ignore all instructions which reference them. Additionally you will need to purchase an O2 sensor block off kit P/N 16925.

Find and unplug the O2 sensor wires from the wiring harness and remove nylon cable tie holding front wire to frame. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE : Pay attention to wire routing for re-installation.
Loosen the heat shield clamps on both the front and rear exhaust pipes. This allows easier access to the head pipe mounting nuts.
Remove the two head pipe exhaust mounting nuts from each flange, located at the cylinder head.
Remove the clamp bolt which mounts 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 exhaust pipes from the motorcycle and set aside.
Using a 14mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system.
Remove the brake rod at the rear junction by removing e-clip and pin.
Remove the drive belt cover and take the bracket off the rear cover bolt, the bracket will not be re-used.
Remove the exhaust mounting bracket by removing the three mount bolts and washers attaching the exhaust bracket (save hardware for re-use) to the motor.
Carefully remove exhaust port flanges and circlips from the stock exhaust system using snaring pliers. NOTE: Replace bent or damaged circlips. Check exhaust port gasket condition and replace if neccessary

VANCE & HINES EXHAUST INSTALLATION

Install exhaust port flanges and circlips on new headers(figure 5).
Install and tighten supplied mounting bracket (stamped 904-P)(Figure 1)

using stock washers and bolts. Torque to 30-33 Ft/Lbs. NOTE: To ease exhaust installation insert one of the 5/8” flange head bolts into the upper right hole of the bracket before installation.

Re-install drive belt cover. Torque the 3/8” bolt to 30-33 Ft/Lbs. and the two 1/4” bolts to 80-120 In/Lbs.
Re-install brake rod into rear junction, replacing pin and e-clip.
Remove header pipes and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Carefully mark outside edge of each heat shield to show location of mounting clips where hose clamps will loop through (Figure 2).

Use a marker for Chrome systems and a pencil for Black systems.

Lay head pipes into heat shields and loosely install hose clamps by feeding tail end of clamp into heat shield clips (Figure 3).

Take note of screw head direction (Figure 4).

Screw heads should be accessible when system is installed on motorcycle for adjustment purposes. Use #20 hose clamps on head pipes and #28 hose clamps on muffler bodies (supplied).

Apply a small amount of anti-seize compound to the threads of the O2 sensors and install them into the new head pipes. Models using 12mm oxygen sensors install 18mm to 12mm oxygen sensor adapter(supplied). Models not using oxygen sensors install 18mm plug. NOTE: Be careful not to get anti-seize on sensor tip, it may affect sensor function.
Using stock flange nuts, carefully install head pipes into exhaust ports (Assistance may be required). NOTE: Do not tighten at this time.
Slide nut plates inside brackets welded to backside of muffler bodies (Figure 6).

While holding nut plates in place, attach muffler bodies to mounting bracket 904-P using four 5/16”x 5/8” flange head bolts (supplied). Leave them loose at this time.

Tighten cylinder port exhaust flange nuts on front and rear cylinders while making sure pipes are parallel.
Tighten the bracket flange head bolts on both mufflers.
Tighten all heat shield clamps.
Plug O2 sensors back into wiring harness and route wires away from hot areas of motorcycle.
Install a new nylon cable tie (supplied) to hold the front wire onto the frame in the original location.
Check for adequate clearance of all exhaust system components and motorcycle accessories prone to heat damage.
After installation and before starting your motorcycle, completely clean pipes and heat shields with warm soapy water and a clean soft cloth. Dry with a clean towel. NOTE: any residue, oil, or fingerprints will stain the finish. Do NOT use anything abrasive to clean the pipes as it may remove the finish.
Be sure to tighten all hardware before starting motorcycle.

EXHAUST CARE (CHROME)

When installing a new set of chrome 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 before starting the motorcycle.
Avoid long periods of idling as this can cause discoloration.
Intake leaks can cause the engine to run lean and overheat, this could lead to discoloration.
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)

When installing a new set of black pipes, make sure your hands are clean and free of oil. After installation, thoroughly 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 the pipes.
Avoid long periods of idling as this can cause discoloration.
Intake leaks can cause the engine to run lean and overheat, this could lead to discoloration.
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.

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.