Vance & Hines BigShot Duals 17927 Motorcycle Exhaust System Installation Instructions

Congratulations, you have purchased the finest exhaust system for your
motorcycle on the market. Your Vance & Hines exhaust system is designed
and crafted for maximum performance, a perfect fit, a great sound and
unbeatable style. Please follow the installation instructions below and if you
have any questions, please call our technical support line at (562) 926-5291.
Attention installer (if other than owner), please forward this instruction sheet
to the owner of this product. These instructions contain valuable information
to the end user.
Snapring pliers
TOOLS
REQUIRED
Flat blade screwdriver
5/16” Nutdriver
1/2”, 9/16” & 7/8” or
22mm Combination
wrenches
1/4” , 3/16”
& 5/16” Allen wrench
s.
Lb
Ft./
Ft./Lb. Torque wrench
3/8” Ratchet &
Extentions, 1/2” Socket,
1/2”, 9/16” & 5/8” deep
sockets,
READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION
1.
2.
STOCK EXHAUST
SYSTEM REMOVAL
MORE POWER : LESS NOISE
HARLEY-DAVIDSON® TOURING MODEL
BIGSHOT DUALS
INSTALLATION INSTRUCTIONS
PART# 17927
3.
4.
5.
6.
7.
8.
Remove both left and right saddlebags and set them aside.
Loosen the bolt from the pinch clamp that attaches the front end of each
muffler to the headers.
Remove the two 5/16” bolts that mount the muffler to the saddlebag
support frame and the OE hanger bracket. Repeat this step on the
opposite muffler.
Remove the stock mufflers and the OE hanger brackets and set them
aside. NOTE: It may be necessary to use a penetrating lubricant to loosen
the muffler from the head pipe.
Find and unplug the O2 sensor wires from the wiring harness and
remove cable tie holding front wire to frame. Feed the end of the wires
through the frame so they are free from the motorcycle. NOTE: Pay
attention to wire routing for re-installation.
Remove the right hand floor board.
Remove the right hand passenger floor board.
Remove the section of the crossover pipe connecting the left side muffler
to the header and then remove the crossover pipe mount bracket on the
FIGURE 1
FIGURE 2
backside of the oil pan. Save the 1/4”-20 x 3/4” screws for re-use.
Loosen the nut and carriage bolt holding the front head pipe to the
bracket on the transmission housing.
10. Loosen the heat shield clamps on both front and rear exhaust pipes to
gain better access to the header flange nuts.
11. Remove the two flange mounting nuts from each head pipe, located at
the cylinder head (these will be re-used). Carefully remove the head pipes
and set them aside.
12. Using a 7/8” or 22mm 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 the stock
exhaust system using snapring pliers. NOTE: If circlips look bent or
twisted, replace them.
14. Replace the OE bracket on the transmission housing with new bracket
514-P)(supplied) and torque to 13-16 ft. lbs. (Figure 1).
(stamped 51415. Carefully remove the stock exhaust gaskets, and replace them with the
supplied exhaust gaskets.
9.
FIGURE 3
Installing
hose clamp
Use stock bolts, tighten to 13-16 ft/Lb
Page 1 of 4
Install 523-P
Shown, 524-P
opposite
FIGURE 4
Arrows indicate
clamp screw
head
direction
TORCA CLAMPS
Mark outside edge
D607IN Rev. 1.1
FIGURE 5
FIGURE 6
FIGURE 7
FIGURE 8
3/8”-16 x 1.5 Flange Head Bolt
3/8” Thin Flat Washer
Chrome Header Clamp
564-P Crossover Bracket
3/8 x 1 x 3/16 Heavy Washer
3/8” Thin Flat Washer
564
Bracket
Torca Clamp
593-P
1” Washer
Installing nutplate
1.
2.
VANCE & HINES EXHAUST
SYSTEM INSTALLATION
3.
4.
5.
6.
7.
8.
9.
10.
11
12.
13.
Install mounting brackets 523-P right side and 524-P left side (supplied) into rubber grommets in
the saddle bag support frame by sliding tabs in from the front. NOTE: Lubrication may be required
to make installation easier. (Figure 2)
Install the crossover bracket (564-P) on the oil pan using stock hardware in the same location as the
stock bracket removed earlier. (Figure 8) NOTE: Do not fully tighten at this time.
Remove head pipes and heat shields from protective packaging. (NOTE: Removal of the end caps
from D580HC and D581HC may be required). Place each heat shield on a non-abrasive surface
such as a blanket or carpet. Using a felt tip pen, mark outside edge of each heat shield to show
location of mounting clips that hose clamps will loop through (Figure 3).
Apply a small amount of anti-seize compound to the threads of the O2 sensors and install them
into the new head pipes. NOTE: Be careful not to get anti-seize on sensor tip, it may affect sensor
function.
Assemble the front header pieces (D559FC, D561FC) using a TORCA band clamp (nut facing down
)(supplied). NOTE: Tighten clamp enough just to hold the assembly together.
Lay the front cylinder head pipe assembly (D559FC, D561FC) into it’s heat shield (D555HC) and
loosely install the hose clamps (supplied) into mounting clips (Figure 3). The smaller #20 hose
clamps are used on the head pipe, the larger #28 are used on the muffler body. NOTE: Screw
heads should be accessible when the system is installed on motorcycle for adjustment purposes
(Figure 4). Do not tighten at this time.
Lay the rear cylinder head pipe (D580FC) into it’s heat shield (D580HC), and install the hose clamps
as in step #6.
First install flanges and then install the circlips from the stock system onto both new head pipes.
Using stock flange nuts, carefully install head pipes onto motorcycle.
Do not tighten at this time.
Install the nut plates and 5/16” x 5/8” flange bolts (supplied) to attach the pipes to the bracket 514P (Figure 5) and the mounting bracket 523-P. Do not tighten at this time.
Align pipes on motorcycle so the gap between the two heat shields is parallel where they run
together. Tighten the exhaust port flange nuts and the 5/16” x 5/8” flange head bolts and finally
the Torca band clamp.
Assemble the left muffler. First slide the header clamp A223CC (supplied) over the end of the
crossover head pipe (D558FC). Next assemble crossover and stub (D558FC,D556RC) together
using a TORCA band clamp (nut facing down) (supplied). NOTE: Tighten the band clamp just
enough to hold assembly together.
Lay the left muffler assembly (D558FC,D556RC) into it’s heat shield (D581HC) and install the hose
clamps as in step #6.
Install TORCA Band Clamp (supplied), with the nut facing down, on the short side expanded end
of the front head pipe (D561FC) (Figure 7).
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Install the left muffler assembly - Slip the end of D558FC into the expanded end of the front header
assembly and using the 5/16”x 5/8” bolts and nut plate (supplied) secure the left muffler assembly
(D558FC,D556RC) to the left bracket 524-P
Referring to Figure 6 - Fasten the crossover pipe to the crossover bracket using supplied hardware.
First place the crossover bracket between the arms of the header clamp. Next
insert the 3/8”-16 x 1.5 flange head bolt with a 3/8” thin flat washer through the header clamp,
crossover bracket, heavy 3/8” washer and once again the arm of the header clamp. Lastly install a
3/8” thin flat washer and 3/8”-16 lock nut. NOTE: Do not tighten at this time.
Align the the left header assembly so it is level with the right side and tighten (in
this sequence) the TORCA band clamp at the muffler body, the 3/8”-16 nut and bolt
enough to hold the 564-P bracket and A223CC clamp together firmly. NOTE: There should
be a slight movement between the pipe and clamp. Next tighten the screws holding bracket to oil
pan to factory specs. Finally tighten the TORCA band clamp at the front header assembly.
Install end caps (if removal was required) and secure with the 1/4”x20 screws removed
earlier. NOTE: Removable thread locking compound on 1/4”x20 screws recommended, end caps
must go into muffler body.
Check alignment of the heat shields and fully tighten all hose clamps, make adjustments as
required.
Plug the O2 sensor wires back into the wiring harness and route wires away from hot areas
of the motorcycle. Use the nylon cable tie (supplied) to secure the front O2 sensor wire to
the frame.
Install Spacer (593-P), on floor board support plate (Figure 8). Remove the left 3/8” socket cap
screw only and place the spacer onto floor board support plate aligning the holes in the spacer
with those on the support plate. Re-install the 3/8” socket cap screw into the original hole
capturing spacer. NOTE: You may use the 3/8” stock socket cap screw to temporarily hold spacer
alignment while tightening the 3/8” socket cap screw.
Install a 3/8” lock washer (supplied) on the 3/8”-16 x 3” socket cap screw (supplied). Using this
bolt re-install the floor board with ONE 1” spacing washer (supplied) (Figure 8) on the forward
(right) mount. NOTE: Spacing washer are located between the floor board supports and floor
board mount plate. On CVO Models, a 3/8”-16 x1-1/2” socket cap screw (not supplied) should
be used from the inside on the right mount rather than the 3/8”-16 x 3” provided bolt.
Re-install the right side passenger floor board and both saddle bags
Be sure to tighten all hardware before starting your motorcycle.
After installation and before starting the motorcycle, completely clean pipes and mufflers
with cleaning solvent and a clean soft cloth that will not leave residue. NOTE: Any residue,
oil, or fingerprints will stain the chrome when the metal heats up.
EXHAUST CARE - HELPFUL HINTS TO AVOID DISCOLORATION OF EXHAUST SYSTEM
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 (chrome wax / polish, glass cleaner, alcohol, ammonia, etc...) before starting the
motorcycle.
2.
3.
4.
Avoid long periods of idling as this can cause discoloration.
Intake leaks can cause the engine to run lean and overheat, this could lead to discoloration.
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.
FUEL MANAGEMENT:
Take the guess work out of fuel injection with Fuelpak Fuel
Management. Contact your local dealer or call (562) 921-0071
to order. Visit fuelpakfi.com for more information.
Fuelpak is intended for racing or off-highway use only, and is
not legal for sale or use in California on pollution-controlled
vehicles.
QUIET
BAFFLE
VANCE & HINES OPTIONAL ACCESSORIES
FUELPAK
MORE POWER : LESS NOISE
3/8”-16 Lock Nut
Quiet baffle P/N 21869 is available for this
system. The quiet baffle will lower the sound
level by 2-3db on average. Contact your local
dealer to order.
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, ground and
cornering clearance may not be improved and in some cases may be reduced. Be sure to follow proper installation instructions.
Page 2 of 4
D607IN Rev. 1.1
HARLEY-DAVIDSON® TOURING MODEL
BIGSHOT DUALS
INSTALLATION INSTRUCTIONS
PART# 17927
PACKING LIST
Nylon Cable Tie x 1
Torca Band Clamp x 3
#20
Hose Clamps x 9
#28
Hose Clamps x 2
ALL PARTS SHOWN ARE ACTUAL SIZE
MORE POWER : LESS NOISE
A223CC Chrome Header Clamp x 1
3/8” Flat Washer x 2
1” x 3/16”
Washer x 2
3/8” Lock Washer x 1
593-P x 1
PARTS NOT SHOWN:
3/8”-16 x 3.0” Socket Head Capscrew x 1
3/8”-16 x 1.5” Flange Head Bolt x 1
5/16” Flange Head Bolt x 8
3/8”-16 Lock Nut x 1
Exhaust Gasket x 2
Nut plate x 4
514-P
564-P
523-P
524-P
D559FC
D561FC
D580FC
D558FC
D556RC
D555HC
D580HC
D581HC
Mounting Bracket
Mounting Bracket
Right Support Bracket
Left Support Bracket
Front Header Front Section
Front Header Rear Section
Rear Cyl Header Assembly
Cross-over Header Assembly
LH Dresser Stub Muffler
Front Cylinder Heatshield
Rear Cylinder Heatshield
Left Side Heatshield
x1
x1
x1
x1
x1
x1
x1
x1
x1
x1
x1
x1
WARRANTY
Vance & Hines exhaust systems are warranted against defects in material and workmanship for a period of 90 days from the date of purchase from an authorized dealer. This warranty does not cover
discoloration of chrome finishes. This warranty is limited to the repair or replacement of a product proven to be defective from normal use. Vance & Hines exhaust systems are designed to fit and
operate on OEM motor and chassis. This warranty does not cover any product subject to abuse, misuse, improper installation or modification.
Page 3 of 4
D607IN Rev. 1.1
FUEL MANAGEMENT
GET THE MOST OUT OF YOUR RIDING EXPERIENCE...
AN AFTERMARKET EXHAUST SYSTEM IS ONLY YOUR FIRST STEP, NOW YOU NEED FUEL MANAGEMENT.
Your fuel injected Harley-Davidson® is equipped with an ECU (electronic
control unit) that’s programmed to deliver fuel to the motor based on an
air/fuel ratio for a stock air filter and stock exhaust system. When you
install a performance exhaust system, your airflow changes, so you
need a fuel management system that adjusts your air/fuel ratio
to match the changes. That fuel management system is Fuelpak.
Fuelpak adds and takes away fuel, allowing for a more precise
range of refinement in your air/fuel ratio. Get the perfect fuel
management combination with your Vance & Hines exhaust
system, get Fuelpak. For more information visit the tuning center at
fuelpakfi.com
NOTICE: Fuelpak is intended for racing or off-highway use only, and is not
legal for sale or use in California on pollution-controlled vehicles.
FISHTAIL TIPS - 16923
BILLET SLASH-CUT TIPS - 16921
MORE POWER : LESS NOISE
NOW YOU NEED FUELPAK.
For even more style, customize your exhaust system
with the Billet Slash-cut end tips.
Fishtail end tips are 100% designed and manufactured by
Vance & Hines and include the same level of quality and performance
as our exhaust systems.
13861 ROSECRANS AVENUE / SANTA FE SPRINGS, CA 90670
SALES: (562) 921-5388 / TECHNICAL: (562) 926-5291 / FAX: (562) 802-0110
VANCEANDHINES.COM
Page 4 of 4
D607IN Rev. 1.1