VANCE HINES 46365 PCX Big Radius 2 Into 2 Exhaust Installation Guide

VANCE HINES 46365 PCX Big Radius 2 Into 2 Exhaust

PRODUCT INFORMATION

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. CH./BLK.| Description| QTY     10     A240HW     Bolt Hex 5/16-18 X 5/8             4
---|---|---|---
1| D766FP| Front Head Pipe| 1       11     A290HW     Bolt Hex 3/8IN-16 X 3/4 Zinc  2
2| D767FP| Rear Head Pipe| 1       12     A270HW     .81-1.75 IN Hose Clamp 5
3| D766HP| Front Heat Shield| 1       13     A272HW     1.31-2.25IN SS Hose Clamp     4
4| D787HP| Rear Heat Shield| 1
5| D322HP-S| Front Muffler Heat Shield| 1
6| D323HP-S| Rear Muffler Heat Shield| 1
7| A288HW| Cable Tie 8inx.14in| 1
8| 499-P| Bracket| 1
9| A195HW| Dog Bone Nut Plate| 2

HARDWARE

TOOLS REQUIRED

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 that is not equipped with O2 sensors, ignore all instructions that reference them. Additionally, you will need to purchase an O2 sensor block-off kit P/N 16925.

1. Remove the seat, locate the rear O2 sensor connector, and unplug the sensor from the harness. Remove the battery and feed the sensor cable end through the frame. NOTE: Pay attention to wire routing for re-installation. Refer to the service manual for proper battery removal.
2. Unplug the front sensor (located behind the rectifier) from the harness and feed the end of the wire through the frame, freeing it from the motorcycle.
3. To gain better access to the flange nuts on cylinder heads, it is recommended that you remove the front and rear heat shields from the exhaust pipes and set them aside.
4. Remove the two mounting flange nuts from each head pipe, located at the cylinder head.
5. Remove the rear cylinder muffler assembly by first removing the two 1/4” flange head bolts from the underside of the rear muffler body.
6. Next, lift the muffler assembly to release it from the crossover pipe and carefully remove the assembly from the motorcycle.
7. Remove the 9/16” nuts attaching the crossover/exhaust mount bracket to the frame.
8. Pull lightly outward to free the crossover mount and carefully remove the front muffler assembly and the crossover pipe from the motorcycle.
9. Using a 14mm wrench, carefully remove the O2 sensors from the stock head pipes and save them for re-use with the new system.
10. Remove the two lower mounting studs from the frame (Figure 1).
11. 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 damaged, Recommended replacement P/N 65324-83B.

VANCE & HINES EXHAUST INSTALLATION

1. At the location where the stock mounting studs were removed (Figure), Install a bracket (stamped 499-P, supplied) using two 3/8’x3/4” flange bolts (supplied) (Figure 1).
2. Remove head pipes and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark the outside edge of each heat shield to show the location of the hose clamp mounting clips (Figure 3).
3. Apply a small amount of anti-seize compound to the threads of the oxygen sensors and install them into the new head pipes (Gray lead was installed into the front head pipe and black lead was installed into the rear head pipe).
   • NOTE : Be careful not to get anti-seize on the sensor tip, it may affect sensor function.
4. Lay head pipes into head pipe heat shields (Figure 2) and loosely install the #20 hose clamps (supplied) into mounting clips (Figure 3).
   • NOTE : Muffler heat shields will be installed after the pipes are on the motorcycle. Screw heads should be accessible when the system is installed on a motorcycle for adjustment purposes (Figure 4). Do not tighten at this time.
5. Install circlips and flanges from the stock system onto both new head pipes.
6. For the CVO Models so equipped, it is recommended that the swing arm bolt chrome cover (right side, with cutout) be removed (Figure 5)
7. Using stock flange nuts, carefully install head pipes onto the motorcycle. Do not tighten at this time.
8. Use the nut plates and 5/16”x5/8” flange bolts (supplied) to attach the pipes to the bracket (Figure 6). Do not tighten at this time.
9. Align pipes on the motorcycle so the gap between the two muffler bodies is consistent from front to rear (Figure 7).
10. Tighten the exhaust port flange nuts, the 5/16”x5/8” flange bolts (supplied), and the 3/8”×3/4” flange bolts (supplied) attaching the bracket to the frame.
11. Using the #28 hose clamps (supplied) install the muffler heat shields Beginning with the D308HC on the front head pipe followed by the D309HC on the rear head pipe. Screw heads should be accessible for adjustment purposes (Figure 4). Do not tighten at this time.
12. Adjust all heat shields for the best alignment at the seam where they meet (Figure 8) and tighten all the hose clamps. Feed connector for the front oxygen sensor (Gray) through the frame and into the holder on the frame behind the rectifier. Plug the sensor into the stock wiring connector.
13. Install a new nylon cable tie (supplied) to hold the wires onto the frame in the original location.
14. Feed wire for the rear O sensor through the frame and under the seat. Reinstall the battery, and plug the sensor into the stock wiring connector.
15. Be sure to tighten all hardware before starting the motorcycle.
16. After installation and before starting the motorcycle, completely clean pipes and mufflers with cleaning solvent and a clean soft cloth that will not leave a residue. NOTE: Any residue, oil, or fingerprints will stain the chrome when the metal heats up.

EXHAUST CARE (CHROME)

1. 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.
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.

EXHAUST CARE (BLACK)

1. 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.
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.

INSTALLATION

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 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.

13861 ROSECRANS AVENUE / SANTA FE SPRINGS, CA 90670

SALES : 562-921-5388
TECHNICAL : 562-926-5291
FAX : 562-802-0110

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