VANCE HINES 2010-2016 Harley-Davidson Touring Models Pro Instruction Manual

VANCE HINES 2010-2016 Harley-Davidson Touring Models Pro

READ ALL INSTRUCTIONS BEFORE BEGINNING THE INSTALLATION
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

TOOLS REQUIRED

Combination Wrench: 1/2”, 9/16”, & 14mm
Flat blade screwdriver
1/4” & 5/16” Nutdriver
3/16” & 5/16” Allen wrench
Snapring pliers
FT/LB Torque Wrench
3/8” Ratchet, extensions, 1/2” socket, 15mm, 9/16” and 5/8” deep well sockets

STOCK EXHAUST SYSTEM REMOVAL

1. Remove both left and right saddlebags and set them aside.

2. Remove the right side panel to gain access to the O2 connections.

3. Loosen the bolt from the pinch clamp on the front end of each muffler.

4. Remove the two 5/16” bolts that mount the muffler to the saddlebag supports. Repeat this step on the opposite muffler.

5. Remove the stock mufflers with sliding hangers and set them aside.

6. Unplug the O2 sensor wires (Grey and Black connectors under the right side panel) from the wiring harness and remove cable ties holding front wire to frame. Feed the end of the wires through the frame so they are free from teh motorcycle.
   NOTE: Pay attension to wire routing for re-installation.

7. Remove the right hand floor board.

8. Remove the right passenger floor board or foot peg if so equipped.

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

10. Remove the nut and carriage bolt holding the front head pipe to the bracket on the transmission housing.

11. Remove the two flange mounting nuts from each head pipe, located at the cylinder head.
    Carefully remove the head pipes and set them aside.

12. Using a 14mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system.

13. Carefully remove the exhaust port flanges and circlips from teh stock exhaust system using snapring pliers. NOTE: if circlips look bent or twisted, replace them.

14. Remove the stock bracket on the transmission housing and install the new bracket (stamped 591-P) (supplied) and torque bolts to 13-16 ft-lbs.
    NOTE: Check clearance between bracket 591-P and OEM wiring harness and adjust if necessary.

15. Inspect the exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. Recommended Harley-Davidson replacement gaskets:#65324-83B.

VANCE & HINES EXHAUST INSTALLATION

1. Remove head pipes and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet large enough to fully protect heat shields. Using felt tip market (chrome system) or a pencil (black system), lightly mark the outside edge of each heat shield to show location of mounting clips that hose clamps will loop. (Figure 2).

2. Lay head pipes into their respective heat shields. Use care when installing the #24 and #20 hose clamps to avoid damaging the coating; install by carefully feeding through the tail end of clamps. Install # 24 hose clamps on the four heat shield clips located closest to the collector end of the heat shield. The #20 hose clamps are inserted into the three other heat shield clips. (Figure 2). Take note of clamp screw head direction (Figure 3). Screw head must be accessible when system is installed on motorcycle for adjustment purposes. NOTE: To avoid excessive movement of heat shield during installation, only fi nger tighten at this time.

3. Apply a small amount of anti-seize compound to the threads of the oxygen sensors and install them into the new head pipe (Grey connector into front head pipe, Black connector into the rear head pipe). NOTE: Be careful not to get anti-seize on sensor tip, it may affect sensor function.

4. Install exhaust port flanges and circlips (from stock system) onto head pipes (Figure 6).
   NOTE: Use care when installing flanges, using a low tack tape (blue painters or equivalent) if necessary to protect the edges of the heat shields from damage.

5. Using stock fl ange nuts, carefully install head pipes into exhaust ports, starting with the rear cylinder. Assistance may be required. NOTE: Do not tighten at this time.

6. Slide the nut plate (supplied) into the bracket that is welded to the back side of the head pipe assembly. Loosely install two 5/16” flange head bolts (supplied) through 591-P bracket into nut plate.

7. Install Torca band clamp with bolt facing down (supplied) onto end of muffl er body (Figure 3 and 7).

8. Install collector heat shield onto header by sliding it on from the rear (Figure 5).
   NOTE: Do not force collector heat shield directlyonto header from the side, damage to collector heat shield will result. Attach collector heat shield with two #24 hose clamps (supplied). NOTE: Finger tighten at this time.

9. Holding the muffler Body (D730RC) in a vertical position (large end down) slip the muffler body heat shield (stamped D734HC) onto the muffler body (stamped D730RC) from front to back and secure with a #44 hose clamp in the front and a #56 hose clamp in the rear. (Figure 3) NOTE: Use care when installing heat shield to avoid damaging the muffler body coating. Use a low tack tape (painters tape or equivalent) to protect the transition on the muffl er body (D730RC) between tapered section and 4.5” round end section during installation. Finger tighten the hose clamps at this time to prevent the heat shield from excessive movement. (Figure 4).

10. Install muffler assembly onto collector of header assembly (Figure 7). Attach muffler assembly to OEM sliding hanger and secure with 5/16” OEM bolts removed earlier.

11. Tighten the exhaust port flange nuts, nut plate bolts, Torca band clamp and 5/16” flange head bolts at the bracket.

12. Tighten hose clamps securing header heat shields and collector heat shield making sure that they are flush. (Figure 5)

13. Tighten muffler body heat shield and leave about 1/16” even gap on the rear between heat shield and muffler body (Figure 4). Make sure top edge of heat shield is aligned with centerline of muffler body to maintain acceptable clearance.

14. Route the front (Grey) and rear (Black) O2 sensor wire along OEM path and plug the grey sensor wire into the grey connector and the black sensor connector into the black connector. Secure wires to the frame using supplied nylon cable ties.

15. Remove the left 3/8” capscrew from the floor board support (Figure 8). Insert the 3/8” capscrew just removed through the second, outer large hole in the spacer marked 593-P (supplied) and re-install the 3/8” capscrew with spacer captured in the original location on the floorboard support. NOTE: Make sure the other, middle large hole on the spacer aligns with the floorboard mounting hole. You may use the 3/8”-16 x 1 1/2 bolt (supplied) to temporarily hold spacer alignment while tightening the 3/8” capscrew.

16. Install a 3/8” lock washer (supplied) on both of the 3/8”-16 bolts (supplied). Using these bolts re-install the fl oor board using a 3/8”-16 x 3” bolt with TWO spacing washers (supplied) on the forward mount and the 3/8”-16 x 1 1/2” bolt with ONE spacing washer (supplied) on the rear mount. NOTE: Spacing washers are located between the floor board supports and floor board mount plate. On CVO Models, a 3/8”-16 x1-1/2” socket head cap screw (not supplied) should be used from the inside on the forward mount rather than the 3/8”-16 x 3” provided bolt.

17. Re-install the passenger floor board and both saddle bags. NOTE: Passenger floorboards can be installed in three positions. Install both passenger floor boards at the middle or upper position.

18. Check for adequate clearance between all exhaust system components and motorcycle accessories prone to heat damage.

19. Be sure to tighten all hardware before starting your motorcycle.

20. After installation and before starting the motorcycle, completely clean pipes and mufflers with soapy water and a clean soft cloth that will not leave a residue. NOTE: Any residue, oil, or fingerprints will stain the finish when the metal heats up.

21. After you have taken the vehicle for a test ride ( to properly heat cycle the exhaust system) it may be necessary to readjust the heat shields to close the gap between the collector heat shield and the head pipe heat shields.

EXHAUST CARE

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 idlling 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.

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.

References

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

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