YAMAHA ROADSTAR 1600/1700 POWERSHOTS EXHAUST

YAMAHA ROADSTAR 1600/1700 POWERSHOTS EXHAUST
YAMAHA ROADSTAR 1600/1700
POWERSHOTS
EXHAUST SYSTEM
Part #18513
CONGRATULATIONS! You have purchased the finest exhaust system available for your motorcycle.
Your VANCE & HINES exhaust system is designed for today's rider, a rider who needs maximum
performance, great styling and a perfect fitting system. Please follow the installation instructions
below and if you have any questions, feel free to call our technical help line (562) 926-5291.
Attention Installer: (if other than owner): Please forward this instruction sheet to the purchaser of
this product. These instructions contain valuable information necessary to the end user.
STOCK EXHAUST SYSTEM REMOVAL
Tools required for installation:
6mm & 8mm Allen wrenches
10mm socket
3/8” Ratchet & Extensions
8, 10, 12 & 17mm Wrenches
1/2” Wrench
5/16” nutdriver/flat blade screwdriver
Ft/lb. & In/lb. Torque wrenches
Brake bleeder & fluid
1. Remove both frame covers. Remove the left cover
first to access a bolt that holds the right side cover
in place.
2. Remove right side floorboard assembly held in place
by two bolts (Figure 1).
3. Remove exhaust port Allen nuts.
4. Remove Allen bolts securing rear muffler to exhaust
system mounting bracket.
5. Remove complete exhaust system. Begin by lifting
muffler out of mounting bracket locating hole (assistance may be required).
6. Check condition of stock exhaust gaskets. Replace if damaged or worn.
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Y405IN Rev. 1.1
7. Remove two bolts attaching stock exhaust mounting bracket to frame.
8. Remove hose clamp securing rear brake hose to exhaust mounting bracket.
9. Remove brake hose banjo bolt from rear caliper.
10. Slide hose out of loop in bracket.
11. Check condition of sealing washers on banjo bolt and
replace if damaged or worn.
12. Reconnect brake hose to caliper (without bracket) and
torque Banjo bolt to 25 lbs. ft.
13. Brake system must be bled or brake will not
operate correctly. Refill reservoir after bleeding.
VANCE & HINES EXHAUST SYSTEM INSTALLATION
1. Remove exhaust system and heat shields from protective
packaging. Place exhaust on a non-abrasive surface such
as a blanket or carpet. Using a non-permanent marker or
tape, mark outside edge of each heat shield to show
location of mounting clips that hose clamps will loop
through (Figure 2).
Figure 1
Allen head bolts
2. Attach brake hose clamp to mounting bracket (stamped
362-P) using one 6x16mm flange bolt and nylock nut
(supplied) to tab located on top of bracket (Figure 2).
Figure 2
attach brake hose
3. Install mounting bracket using two 10x30mm Allen bolts
and lock nuts (supplied)(Figure 3).
4. Carefully slide heat shields onto headers.
5. Loosely install each hose clamp by feeding tail end of
clamp into heat shield clip (Figure 4). Use #20 hose
clamps for head pipe areas and #36 hose clamps for
muffler areas. Take note of clamp screw head direction
(Figure 5). Screw head should be accessible when
system is installed on motorcycle for adjustment
purposes. Note: Do not tighten yet.
6. Using stock Allen nuts, carefully install system into
exhaust ports starting with the rear port first.
(Assistance may be required). Note: Do not tighten yet.
7. Slide dog bone shaped nut plate (supplied) inside each
bracket welded to backside of mufflers (Figure 6).
8. Attach mufflers to mounting bracket (362-P) using
5/16” flange bolts (supplied) engaging dog bone nut
plate. Note: Do not tighten yet.
Figure 3
Mark
outside
edge
Install bracket
Feed clamp
through clips
Figure 4
9. Tighten exhaust port flange nuts securing head pipes to cylinder heads.
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Y405IN Rev. 1.1
10. Tighten 5/16” flange bolts securing mufflers to
mounting bracket.
Black arrows indicate the
direction of clamp heads
11. Slide muffler heat shield (K342HC) on from the rear and
loosely install four #36 hose clamps. Note position and
direction of screw heads (Figure 5).
12. Be sure the rear of the muffler extends 1/4” beyond the
end of the heat shield (Figure 7).
Figure 5
13. Tighten clamps on head pipe heat shields.
14. Tighten hose clamps on muffler heat shield. Check that
heat shield is centered on the muffler bodies when
viewed from the rear (Figure 8).
15. Reinstall right side floorboard. Some models require
spacers to provide adequate clearance to exhaust pipe.
If necessary, install 1/2” x 1” spacers and 10 x 25mm
button head allen bolts to space out floorboard.
Figure 6
Install nutplate
16. Reinstall side covers, right side first.
1/4”
17. Check for adequate clearance between all exhaust
system components and motorcycle accessories prone
to heat damage.
18. After installation and before starting 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.
5/16”
Figure 7
19. All hardware must be properly tightened before starting
motorcycle.
Check alignment
of heat shield
from rear
RE-JETTING INSTRUCTIONS
Re-jetting the carburetors will result in realizing the "full"
potential of this performance exhaust system. Vance &
Figure 8
Hines offers jet kits for most applications. For fuel injected
models, we recommend the use of an adjustable fuel management system.
PLEASE NOTE: Ever y effor t is made for Vance & Hines Exhaust Systems to provide improved
cornering clearance. However, due to design and space limitations on some motorcycle models,
(center stand, oil filter, oil pan etc.) ground and cornering clearance may not be improved and in some
cases may be reduced. Be sure to follow proper installation instructions.
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Y405IN Rev. 1.1
PACKING LIST (All parts actual size)
10 x 30mm
Allen bolt x 2
10 x 25mm Button
head Allen bolt x 2
#20 Hose clamp x 6
6mm nylock
nut x 1
10mm lock nut x 2
6 x 16mm
Flange bolt x 1
1/2” x 1” spacer x 2
5/16” Flange
bolt x 4
#36 Hose clamp x 4
Nutplate x 2
1.
2.
3.
4.
5.
HELPFUL HINTS TO AVOID DISCOLORATION OF EXHAUST PIPES
Follow owner’s manual instructions regarding use of the choke (starter enricher). If left on longer
than recommended, discoloration may be accelerated.
Avoid long periods of idling.
Intake leaks can cause engine to run lean and overheat, thus turning the pipes blue.
Make sure there are no exhaust leaks at the junction of the exhaust pipe and cylinder head.
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 cleaning solvent that will leave no residue (glass
cleaner, alcohol, ammonia, etc.) before starting the motorcycle.
WARNING!
VANCE & HINES DOES NOT WARRANTY ANY CHROME
PRODUCTS AGAINST DISCOLORATION.
For information about other Vance and Hines products visit our web site at www.vanceandhines.com
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