ROAD STAR WARRIOR BIG SHOTS EXHAUST SYSTEM

ROAD STAR WARRIOR BIG SHOTS EXHAUST SYSTEM
ROAD STAR WARRIOR
BIG SHOTS
EXHAUST SYSTEM
Part # 18505
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
1. Remove right side rider and passenger footpeg
assemblies. (Save footpegs and bolts for future
reassembly. Do not disconnect brake master cylinder
plunger rod.)
Figure 1
2. Remove front cylinder exhaust port flange nuts. (Save)
3. Remove rear cylinder exhaust flange bolts. (Save)
4. Remove two bolts connecting muffler mounting bracket
to lower frame rail.
5. Remove bolt connecting muffler to upper muffler
bracket. Carefully remove complete system from
motorcycle. (Assistance is recommended.) Note: Apply
tape on crank case area just in front of rear head pipe
bend to protect paint during dissassembly and
Figure 2
assembly.
6. Remove M6 x 35 button head screws connecting rear
brake master cylinder reservoir to stock muffler bracket.
(Do not disconnect hose. Save screws.)
7. Remove stock upper muffler bracket. (Save M10 x 25
button head bolts for reassembly.)
VANCE & HINES EXHAUST SYSTEM INSTALLATION
1. Check condition of stock exhaust gaskets. Replace if
damaged or worn.
Figure 3
2. Install rear brake master cylinder reservoir bracket
(stamped 333) using saved M10 x 25 bolts and supplied
M10 lock nuts (Figure 1).
3. Attach rear brake master cylinder reservoir to bracket
(stamped 333) using saved M6 x 35 screws and
Mark
supplied M6 lock nuts (Figure 1).
outside
4. Install and tighten mounting bracket (stamped 336) to edge
frame using supplied M10 x 25 button head allen bolts
Feed clamp
(Figure 2), If required, M10 flat washers are provided to
through clips
space bracket away from frame casting ridge.
Figure 4
5. Place heat shields on a non-abrasive surface such as a
blanket or carpet. Mark outside surface of front and rear heat shields with location of mounting
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Y395IN Rev. 1.0
6.
7.
8.
9.
10.
11.
12.
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16.
clips welded to the inside using a felt tip marker (Figure
Arrows indicate direction of clamp
4).
heads
Install each heat shield over its respective head pipe
(Figure 3).
Install each hose clamp by feeding tail end of clamp into
heat shield clip (Figure 4). Take note of clamp screw
head direction (Figure 5). Screw head should be
accessible when system is installed on motorcycle for
adjustment purposes. Use #20 hose clamps for head
Figure 5
pipe areas and #28 hose clamps for muffler areas. Note:
Prior to tightening hose clamps, align heat shields so
that slash ends are even (Figure 6).
Tighten all hose clamps securing heat shields.
Carefully install system into exhaust ports (front port
first) using stock flange nuts and bolts. Assistance is
recommended. Slide dog bone shaped nut plate
(supplied) inside each bracket welded to backside of
mufflers (Figure 7). Attach mufflers to mounting bracket
Figure 6
336 using 5/16” flange bolts (supplied) engaging dog
bone nut plate.
Installing
Tighten exhaust port flange nuts and bolts securing
dog bone
head pipes to cylinder heads.
nut plate
Tighten 5/16” flange bolts securing mufflers to
mounting bracket.
Install and tighten both rider and passenger footpegs.
Check for adequate clearance between all exhaust
system components and motorcycle accessories prone
to heat damage.
Figure 7
Remove protective tape from crank case area, as well as
oil and finger prints from chrome using a soft cotton cloth and chrome polish before starting
engine.
All hardware must be properly secured before operating motorcycle.
Rear brake must be functioning correctly before operating motorcycle.
FUEL-INJECTION INSTRUCTIONS
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.
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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Y395IN Rev. 1.0
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