KAWASAKI VULCAN 2000 POWERSHOTS EXHAUST SYSTEM

KAWASAKI VULCAN 2000 POWERSHOTS EXHAUST SYSTEM
KAWASAKI VULCAN 2000
POWERSHOTS
EXHAUST SYSTEM
Part #18311
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 installations
1. Remove right side frame cover.
6mm Allen wrench
2. If motorcycle is oxygen sensor equipped, remove
passenger seat. Remove two bolts securing operator seat
8, 10, 12, & 14mm sockets
and set seat aside. Locate and unplug oxygen sensor
3/8” Ratchet & Extensions
connector from wiring harness (Figure 1).(Note wire
19mm & 22mm Wrench
routing for reassembly).
9/16 Wrench
3. Remove right side floorboard assembly held in place by
Brake bleeder & fluid
two bolts (Figure 2).
4. Remove rgh side saddlebag, if equipped.
5. Remove exhaust port flange nuts.
6. Remove flange bolts securing both mufflers to exhaust system mounting bracket.
7. Remove complete exhaust system. Start by removing front head pipe from exhaust port
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K400IN Rev. 1.2
(assistance may be required).
8. Check condition of stock exhaust gaskets. Replace if
damaged or worn.
9. Remove plastic hose clamp securing rear brake hose to
swingarm.Save for re-use.
10. Remove brake hose banjo bolt from rear caliper.
11. Slide hose out of loops in swingarm.
12. Remove three bolts holding stock exhaust mounting
bracket and slide bracket off end of brake hose.
13. Slide brake hose through loop on new bracket (stamped
357-P) and install to the original mounting bracket
location, using three 8mm x 16mm Allen bolts (supplied)
(Figure 3).
14. Check condition of sealing washers on banjo bolt and
replace if damaged or worn.
15. Slide brake hose through loops on swingarm and
reconnect brake hose to caliper.
16. Reinstall plastic clip onto swingarm.
17. Brake system must be bled or brake will not
operate correctly.
Figure 1
Figure 2
Floorboard bolts
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 nonpermanent marker or tape, mark outside edge of each
heat shield to show location of mounting clips that hose
clamps will loop through(Figure 4).
2. If motorcycle is oxygen sensor equipped, unscrew the
sensor from the stock exhaust system and install it into
Figure 3
the Vance & Hines exhaust system. Note: Use caution
when handling. Do not touch sensor tip area.
3. If motorcycle is not oxygen sensor equipped, install
18mm plug and washer (supplied) into the oxygen
sensor boss.
4. Carefully slide heat shields into headers.
Mark
5. Loosely install each hose clamp by feeding tail end of
clamp into heat shield clip (Figure 4). Take note of clamp outside
Feed clamp
edge
screw head direction (Figure 5). Screw head should be
through clips
accessible when system is installed on motorcycle for
adjustment purposes.
Figure 4
6. Using stock flange 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 (357-P) using 5/16” flange bolts (supplied) engaging dog
bone nut plate. Note: Do not tighten yet.
9. Tighten exhaust port flange nuts securing head pipes to cylinder heads.
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K400IN Rev. 1.2
10. Tighten 5/16” flange bolts securing mufflers to mounting
bracket.
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. Make sure the rear of the muffler extends 1/4” beyond
the end of the heat shield (Figure 7).
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. Check for adequate clearance between all exhaust system
components and motorcycle accessories prone to heat
damage.
16. 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.
17. All hardware must be properly tightened before starting
motorcycle.
Black arrows indicate the
direction of clamp heads
Figure 5
Oxygen sensor
Figure 6
1/4”
5/16”
Figure 7
Check alignment of
heat shield from rear
FUEL-INJECTION INSTRUCTIONS
Figure 8
For fuel injected models, Vance & Hines recommends the use
of an adjustable fuel management system to ensure maximum exhaust system performance.
PLEASE NOTE: Every effort 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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K400IN Rev. 1.2
PACKING LIST (All parts actual size)
18mm plug x 1
18mm Washer x1
#20 Hose clamp x 6
Nutplate x 2
5/16” Flange
bolt x 4
8mm Allen
bolt x 3
# 36 Hose clamp x 4
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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K400IN Rev. 1.2
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