Installation
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.
TOOLS
REQUIRED
Flat blade screwdriver
Snapring pliers
5/16” Nutdriver
1/2”, 9/16” & 7/8”
Combination wrenches
3/16” & 1/4”
Allen wrenches
3/8” Ratchet &
extensions
7/16”, 1/2” & 9/16”
Sockets
READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION
1.
STOCK EXHAUST
SYSTEM REMOVAL
MORE POWER : LESS NOISE
HARLEY-DAVIDSON® DYNA
BIG RADIUS
INSTALLATION INSTRUCTIONS
PART# 46013
2.
3.
4.
5.
6.
7.
Remove seat to gain access to rear oxygen sensor connector.
Unplug sensor and feed end of wire through frame to free it
from motorcycle. NOTE: Pay attention to wire routing for reinstallation.
Remove two bolts holding rectifier onto front of frame (near
front tire). Open plastic cover to gain access to front oxygen
sensor connector. Unplug sensor from harness. Remove cable
tie holding wire to frame and feed end of wire through to free it
from motorcycle.
Loosen heat shield clamps on both the front and rear head pipes.
Remove two cylinder exhaust port flange nuts from each head
pipe, located at the cylinder head.
Remove front head pipe clamp bolt.
Remove the bolt that attaches mufflers to the frame mounting
bar.
Remove the mounting bar attaching front and rear mufflers.
FIGURE 1
8.
Remove the complete exhaust system and set aside (Assistance
may be required).
9. Remove stock mounting bar and the studs in the transmisson
cover. Save the bolts, one will be re-used.
10. Remove left bolt below the transmission cover. Position mounting
bracket 391-P over mounting location to determine which bolts
to remove (Figure 1). Install this bolt in the top hole left vacant by
the new bracket.
11. Carefully remove the flanges and circlips from the stock exhaust
system using snapring pliers. NOTE: Replace bent or damaged
circlips. Check condition of stock exhaust gaskets. Replace if worn
or damaged. (Recommended replacement exhaust port gaskets,
Screamin’ Eagle part number 17048-98).
12. Remove stock oxygen sensors, they will be re-used on new
system.
FIGURE 2
TRANSMISSION COVER
INSTALL ALLEN BOLT REMOVED
FROM LOWER HOLE
Installing
circlip
INSTALL SPACER BETWEEN
BRACKET AND MOTOR
Flange
BRACKET 391-P
USE 5/16"-18 X 1-1/2" HEX
BOLTS AND WASHERS (SUPPLIED)
Page 1 of 4
REMOVE ALLEN BOLT
PRIOR TO INSTALLING
MOUNTING BRACKET
D750IN Rev. 1.1
FIGURE 3
FIGURE 4
Mark outside edge
1.
VANCE & HINES EXHAUST
SYSTEM INSTALLATION
2.
3.
4.
5.
6.
7.
8.
FIGURE 6
Installing nutplate
Attach mounting bracket 391-P (supplied) to transmission using the
11/16’ spacer and three 5/16” x 1-1/2” hex bolts and 5/16” flat washer
combinations (supplied) (Figure 1). NOTE: The 11/16” spacer and longer bolt
are not required for 2006-2007 models.
Install circlips and flanges from the stock system onto both new head pipes
(Figure 2).
Apply a small amount of anti-seize compound to the threads of the oxygen
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.
Remove head pipes and heat shields from protective packaging. Place each
heat shield on a non-abrasive surface such as a blanket or carpet. Using
a pencil, lightly mark outside edge of each heat shield to show location
of mounting clips where hose clamps will loop through (Figure 3). NOTE:
Pencil marks can be erased if care is taken not to harm coating.
Lay head pipes (D535FP & D536FP) into head pipe heat shields (D535HP &
D536HP) respectively. Make sure alignment clip on head pipe fits inside heat
shield. Loosely install #20 hose clamps by feeding tail end of clamp into
heat shield clips (Figure 3). Take note of screw head direction (Figure 4).
Screw head should be accessible when system is installed on motorcycle for
adjustment purposes. NOTE: Do not tighten at this time.
Using the #28 hose clamps install the muffler heat shields with the D322HP
on the front head pipe and the D325HP on the rear. Take note of screw
head direction (Figure 4). NOTE: Do not tighten at this time.
Using stock flange nuts, carefully install head pipes into exhaust ports,
starting with the rear cylinder. Assistance may be required. NOTE: Do not
tighten at this time.
Slide nutplates inside brackets that are welded to backside of each muffler
body (Figure 5). While holding nutplates in place, attach muffler bodies to
mounting bracket 391-P using four 5/16”x 5/8” flange head bolts (supplied).
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Align gap between mufflers
Leave them loose at this time. NOTE: Muffler body brackets should align
with edges of mounting bracket 391-P.
Align pipes on motorcycle so that the gap between the two muffler bodies
is consistent from front to rear and tighten exhaust port flange nuts (Figure
6).
Tighten flange bolts securing muffler bodies to mount bracket 391-P.
Adjust the heat shields to get the best alignment at the seam where they
touch (Figure 6) and tighten all the hose clamps.
Feed wire for front oxygen sensor through frame and into plastic holder on
frame. Plug sensor into stock wiring connector. Snap plastic holder closed to
hold connector in place.
Put toothed edge of wiring holder into slot in frame. Re-install rectifier so
that it fits under tooth of wiring holder, keeping it in place in frame. Tighten
both bolts.
Install a new cable tie (supplied) to hold wires onto frame in original
location.
Feed connector for rear oxygen sensor through frame and into underseat
compartment. Plug sensor into stock wiring connector.
Re-install seat.
Check for adequate clearance between all exhaust system components and
motorcycle accessories prone to heat damage.
After installation and before starting your motorcycle, completely clean pipes
and heat shields with warm soapy water and a clean soft cloth. Dry with
a clean towel. NOTE: any residue, oil, or fingerprints will stain the black
coating. Do NOT use anything abrasive to clean the pipes as it may remove
the finish.
Be sure to tighten all hardware before starting motorcycle. We also
recommend checking that the Chrome end cap screws are tight from time
to time.
EXHAUST CARE - HELPFUL HINTS TO AVOID DISCOLORATION OF EXHAUST SYSTEM
1.
When installing a new set of black pipes, make sure your hands are clean and free of oil. After
installation, thoroughly clean pipes with warm soapy water and a soft cloth. Dry with clean
towel to remove any residue before starting the motorcycle. Do NOT use anything abrasive to
clean pipes.
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.
VANCE & HINES OPTIONAL ACCESSORIES
FUELPAK
MORE POWER : LESS NOISE
FIGURE 5
Arrows indicate clamp
screw head direction
Installing
hose clamp
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.
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
D750IN Rev. 1.1
HARLEY-DAVIDSON® DYNA
BIG RADIUS
INSTALLATION INSTRUCTIONS
PART# 46013
Nylon cable tie x 1
ALL PARTS SHOWN ARE ACTUAL SIZE
MORE POWER : LESS NOISE
PACKING LIST
#28 Hose clamps x 4
#20 Hose clamps x 5
11/16” x 9/16”
Spacer x 1
5/16” x 5/8” Flange head bolts x 4
5/16” x 1-1/2” Hex head bolts x 3
Nutplates x 2
5/16” Flat washers x 3
PARTS NOT SHOWN:
391-P
Bracket
x1
D535FP
Front head pipe assy
x1
D536FP
Rear head pipe assy
x1
D535HP
Front heat shield
x1
D536HP
Rear heat shield
x1
D322HP
Front muffler heat shield x1
D325HP
Rear muffler heat shield 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
D750IN 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.
MORE POWER : LESS NOISE
NOW YOU NEED FUELPAK.
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.
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
D750IN Rev. 1.1
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