VANCE HINES 27331 Big Shots Duals Exhaust System Instruction Manual

VANCE HINES 27331 Big Shots Duals Exhaust System Instruction Manual

INSTALLATION INSTRUCTIONS

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.| Description| Qty.|
---|---|---|---|---
1     D320RB-S/D325RP-S     MUFFLER CAN ASSY| 1| 10| A260SP| SPRING PULLER| 1
2| D1128FB/D1328FP| FRONT HEAD PIPE| 1| 11| 1164-P| RHS RELOCATOR| 1
3| D1129FB/D1329FP| REAR HEAD PIPE| 1| 12| 1168-P| LHS RELOCATOR| 1
4| 1198-P/1199-P| BRACKET| 1| 13| A908HW| 3/8”-16 X 1IN SHCS| 2
5| A115SP| SPRING| 2| 14| A909HW| 3/8”-16 X 1.75IN SHCS| 2
6| A240HW| 5/16”-18 X 5/8IN FHS| 2| 15| A912HW| 3/8”-16 X 1-3/8IN SHCS| 2
7| A742HW| 3/8”-16 X 1.0 12PT SCREW| 2| 16| A914HW| 3/8”-16 X 7/8IN SHCS| 2
8| A644ST| 18-12MM O2 ADAPTOR| 2| 17| A868HW-P| .750 OD X .500IN SPACER| 1
9| A195HW| DOGBONE NUT PLATE| 1| 18| A874HW| 5/16”-24 X 1.50IN BHCS| 1
| 19| A435HW-B| 5/16”-18 X 5/8IN BHCS| 1

HARDWARE

• Flat Head Screwdriver
• Combination Wrenches: 1/2”, 9/16”, 14mm, 17mm, 19mm
• Allen Wrenches: 1/4”, 5/32”, 3/16”, 5/16” Torx: T45
• 5/16 Nut Driver
• 3/8” Drive Ratchet w/ 4” extension 1/2”, 9/16” Deep Sockets 3/8” 12pt Socket, 1/4” Allen Socket 10mm, 19mm Socket
• Snap Ring Pliers

STOCK EXHAUST SYSTEM REMOVAL

1. Locate the rear O2 sensor connector. Remove the two bolts holding the right side cover in place and gently pull cover off bike.
   NOTE: Pay attention to the wire routing for re-installation.

2. Locate the front O2 sensor connector. Unplug the sensor and feed the end of the wire through the frame, freeing it from the motorcycle.

3. On Floor board models, loosen the right-hand floor board mounting bolts to gain clearance for the exhaust removal and installation.

4. On Mid Mount models, remove the forward brake rod bolt and remove the mid mount foot peg bracket.

5. Loosen the heat shield clamps on both the front and rear exhaust pipes.

6. Remove the two mounting nuts from each head pipe, located at the cylinder head.

7. Remove the bolts attaching the mufflers to the mounting bracket.

8. Remove the entire exhaust system and set it aside.

9. Remove the stock mounting bracket.

10.  Carefully remove the exhaust port flanges and circlips from the stock exhaust system using the snap ring pliers.
    NOTE: Replace bent or damaged circlips.

11.  Carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system.

12. Check the condition of the exhaust gasket and replace if worn or damaged. Harley-Davidson part number 65324-83B.

VANCE & HINES EXHAUST INSTALLATION

NOTE:
Use appropriate Harley-Davidson service manual procedures when referring to exhaust installation.

1. Install 1198-P bracket onto frame using the supplied 12pt ARP flange head bolt
   (Figure 1).
   Note: use 1199-P bracket for Heritage and Sport Glide models with saddlebags. Prior to installing 1199-P attach stock saddlebag support grommet to bracket with supplied hardware (Figure 11).

2. Remove head pipes from their protective packaging. Place each head pipe on a non-abrasive surface such as a blanket or carpet.

3. Install circlips and flanges from the stock system onto both the new head pipes.

4. Apply a small amount of anti-seize compound to the threads of the O2 sensors and install them into the new head pipe. Install supplied 18mm to 12mm oxygen sensor adapter then install 12mm oxygen sensors.

5. Install the front header assembly (D1128FB/D1328FP) into the front exhaust port first. Use the stock flange nuts, do not tighten at this time (Figure 2).

6.  Install the rear header assembly (D1129FB/D1329FP) into the exhaust port. Use the stock flange nuts, do not tighten at this time (Figure 2).

7. Slide the dog bone nuteplate (A195HW) onto the mounting bracket and slip muffler can onto front and rear head pipes. Hand tighten muffler can using supplied 5/16-18 flange head bolts (A240HW, x2) (Figure 3).

8.  Tighten the exhaust system nut, bolts, and clamps in the following sequence: (1) Head flange nuts (x4), (2) Muffler body 5/16-18 flange head bolts (A240HW, x2). Make sure the head pipes and mufflers are aligned parallel, and ensure proper & even spacing between cam cover and rear head pipe (Figure 4).

9.  Install springs using supplied spring puller; there should be about 2” between spring tabs (Figure 5).

10. Route O2 sensor wires away from hot areas of the motorcycle. Plug the O2 sensor wires back into the wiring.

11. Steps 12- 17 are for mid mount models, where the mid control spacer kit is required.

12. Install right hand side relocator (1164-P) using 3/8-16 X 1.75IN (A909HW, x2) (Figure 6).

13. Loosely install mid control using using 3/8-16 X 7/8IN SHCS (A914HW, x2) (Figure 7).

14. Install spacer (A868HW-P) and attach brake rod using 5/16-24 X 1.50IN BHCS (A874HW)(Figure 8).

15. Fully tighten hardware from step 13.
    NOTE: Adjust brake rod and mid controls to ensure that brake rod does not contact the front head pipe when brake is applied.

16. . Install left hand side relocator (1168-P) using 3/8-16 X 1IN (A908HW, x2) (Figure 9).

17. Install mid control using 3/8-16 X 1-3/8IN SHCS (A912HW, x2).

18. For models with passenger foot peg attached to the stock exhaust bracket, remove the upper plug on the frame and re-install the left and right passenger foot pegs into the upper mounting holes (Figure 10).

19. Be sure to tighten all hardware before starting motorcycle. After installation and before starting the motorcycle, completely clean pipes and mufflers with soapy water and a clean soft cloth.
    NOTE: Any residue, oil, or fingerprints will stain the finish when the metal heats up.

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.

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.

• 13861 ROSECRANS AVENUE / SANTA FE SPRINGS, CA 90670
• SALES: 562-921-5388
• TECHNICAL: 562-926-5291
• FAX : 562-802-0110

References

• CALIFORNIA CUSTOMER - Vance & Hines
• Home Page - Vance & Hines

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