yamaha road star pro pipe hs exhaust system

yamaha road star pro pipe hs exhaust system
YAMAHA ROAD STAR
PRO PIPE HS
EXHAUST SYSTEM
Part #25501
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 at (562) 926-5291.
REMOVING THE STOCK EXHAUST SYSTEM
1. Remove the header flange nuts from the rear cylinder.
2. Loosen right side floor board allowing clearance for front head pipe removal.
3. Loosen the muffler clamp on front head pipe.
4. Remove the two muffler mounting bracket bolts, located between mufflers.
5. Carefully separate the front head pipe from muffler assembly. Remove muffler assembly with
rear head pipe attached and set it aside.
6. Remove the header flange nuts from front cylinder. Remove front head pipe and set it aside.
7. Remove the muffler mounting bracket from frame. Note: The rear brake hose must be
disconnected from the rear brake caliper in order to remove the muffler mounting bracket.
INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM
1. Reconnect brake hose to rear caliper. Important: Bleed the rear brake to remove any air
from the system and refill the reservoir with the proper brake fluid. Refer to owners
manual.
2. Install mounting bracket (stamped 315) to frame. Align two 10mm holes in bracket with holes in
the frame below the right rear footrest (where the stock mounting bar was removed). Use two
10mm bolts and lock nuts (supplied), do not tighten at this time. Note: The bracket will bend
away from the motorcycle when
mounted correctly. (Refer to
figure 1.)
3. Connect brake hose clip to
megaphone mounting bracket,
using 6mm bolt and lock nut
(supplied). (Refer to figure 1)
4. Check condition of stock
exhaust gaskets. Replace
damaged or worn gaskets.
5. Unscrew all hose clamps
(supplied) until they are
VIEW FROM RIGHT SIDE OF MOTORCYCLE
FIG. 1
completely loose. Mark top
edge of all three heat shields
with the location of mounting clips that are welded to backside. Place header on non-abrasive
surface such as a blanket or carpet. (Reduces risk of scratching chrome on heat shields)
Position front heat shield over head pipe and feed tail end of hose clamps into clips. Be sure
that each hose clamp is engaged with both clips. Repeat this step with rear heat shield and
FRAME MOUNTING HOLES
MUFFLER MOUNTING HOLES
Page 1 of 2
BRAKE HOSE MOUNTING HOLE
Y385IN Rev. 1.0
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
collector heat shield. To facilitate installation of collector heat shield, use a forward sliding
motion from rear of the collector. Do not force collector heat shield directly onto header
from the side. Damage to heat shield will result. Note: Collector heat shield uses smaller
POSITION FRONT EDGE OF
3/8” wide clamps.
COLLECTOR HEAT SHIELD
REAR EDGE OF COLLECTOR
COLLECTOR COLLAR WELD SEAM
COLLAR WELD AND SLIDE FORWARD
Install the header using stock AT
HEAD PIPE HEAT SHIELD
HEAD PIPE HEAT SHIELDS
flange nuts, do not tighten at
HEAD PIPE
HEAT SHIELD CLIP
WELD SEAMS
this time.
Install megaphone clamp
(supplied) over inner slip joint
tube at front of megaphone.
Slip megaphone onto head pipe
COLLECTOR
collector, engaging collector
CLAMP
SLIDE FORWARD AND DOWN (MAY REQUIRE SOFT MALLET)
COLLECTOR HEAT SHIELD
heat shield between
HEAT SHIELDS SHOULD MATCH FLUSH
FIG. 2
megaphone clamp and outer
slip joint tube. Slide one dog
bone shaped nut plate under bracket that is welded to the backside of the megaphone and
attach to mounting bracket using two 5/16” flange head bolts (supplied).
Tighten mounting hardware in the following order: 1. Head pipe flange nuts, 2. Megaphone
clamp, 3. Flange bolts at megaphone to mounting bar attachment.
Align all three heat shields so ends meet flush. (Refer to figure 2). Tighten heat shield clamps.
Tighten the two 10mm bolts that mount the bracket to the frame.
Check for adequate clearance between all exhaust system components and motorcycle
accessories prone to heat damage.
Remove oil and finger prints from chrome using a soft cotton cloth and chrome polish before
starting engine.
Be sure to tighten all hardware before starting your motorcycle.
Be sure the rear brake is functioning properly before riding.
RE-JETTING INSTRUCTIONS
Re-jetting the carburetors will result in realizing the "full" potential of this performance exhaust
system. Vance & Hines offers jet kits for most applications. For fuel injected models, we recommend
the use of an adjustable fuel management system.
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.
For information about other Vance and Hines products visit our web site at vanceandhines.com
WARNING!
VANCE & HINES DOES NOT WARRANTY ANY CHROME
PRODUCTS AGAINST DISCOLORATION.
Page 2 of 2
Y385IN Rev. 1.0
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