installation instructions: harley-davidson softail hi-output

installation instructions: harley-davidson softail hi-output
INSTALLATION INSTRUCTIONS:
HARLEY-DAVIDSON SOFTAIL
HI-OUTPUT GRENADES 2-INTO-2
PART# 16846/16848/46846/46848
Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your Vance & Hines exhaust
is designed and crafted for performance, quality, and style. Please follow the instructions below, check exhaust system for
missing or damaged parts and if you need any assistance please contact our technical support line (562) 921-7461.
5
4
2
1
6
3
7
PARTS LIST
NO.
Description
Qty.
9
1/4-20 x 1/2 Flange Bolt
4
1
Front Head Pipe
1
10
3/8-16 X 1 1/2 IN. FHCS
1
2
Rear Head Pipe
1
11
Bracket Spacer
1
3
Front Heat Shield
1
12
18mm X 24mm Washer
2
4
Rear Heat Shield
1
13
18-12mm O2 Adapter
2
5
Mount Bracket
1
14
18mm X 1.5mm X10mm Plug
2
6
Muffler Front
1
15
T-Bolt Clamp
2
7
Muffler Rear
1
16
#20 Hose Clamp
7
8
3/8-16 X 3/4 IN. FHS
2
Page 1 of 6
D925IN RevC
HARDWARE
10
14
16
13
8
12
15
9
11
TOOLS REQUIRED
5/16” Nut Driver
Flat blade Screwdriver
#3 Phillips Head
Combination Wrench:
1/2”, 9/16”,7/8”
14mm, 22mm
3/8” Ratchet, extensions
19mm, 1/2” Socket
3/4” & 9/16” Deep Socket,
7/16” Deep Socket
Allen Wrenches: 5/16”
Snapring Pliers
T45 & T50 Torx wrenches
10
17
Page 2 of 6
D925IN RevC
STOCK EXHAUST SYSTEM REMOVAL
1. On FLSTC, FLSTF, and FLSTN, loosen the right hand floor board mounting bolts to gain clearance
for exhaust removal and installation.
2. Unbolt the carriage bolt and clamp attached to the bracket located under the right side
transmission cover.
3. Loosen crossover pipe clamp located between front and rear head pipes and.
4. Loosen the heat shield clamps on both front and rear exhaust pipes.
5. Remove the two mounting nuts from each head pipe.
6. Remove the nuts attaching the exhaust mounting bracket to the frame.
O2 SENSOR EQUIPPED MODELS (2007-PRESENT)
7. Rear O2 Sensor, Locate the O2 sensor connector, unplug the connector from the main harness
and feed the wire through the frame to free it from the motorcycle. Pay attention to wire routing
for re- installation. NOTE: For 2007 to 2011 Models the connector is located under the oil tank, on
the right side. For 2012 & later models the connector is located under the seat, remove both the
seat and battery for access.
8. Front O2 sensor, Locate the O2 sensor connector at the front of the motorcycle, unplug connector
from harness, and free the sensor lead from the motorcycle. NOTE: For 2007 to 2011 Models,
Open the plastic cover above the rectifier to gain access to the sensor plug, cut the cable ties
holding the sensor wire to frame. For 2012 & later models the connector is located behind the
voltage regulator.
9. Remove the exhaust system and set it aside. Assistance may be required.
10. Remove the stock mounting bars, brackets and/or studs.
PRE 2000 Models: Remove the lower mounting bar. Remove the right side 1/4” bolt which
holds the lower fender in place to allow removal of the right passenger foot peg. Place the
motorcycle on its side stand and loosen the swing arm pivot bolt nut. Position a floor jack under
the right hand frame tube just below the swing a pivot bolt. Using assistance, carefully raise the
jack just enough to take the weight off the swing arm bolt and remove the swing arm pivot bolt
and the stock upper mounting bar, Replace the swing arm pivot bolt and torque to 135 FT/LB.
2000 & Later Models: Using a T50 Torx driver, remove the three mounting bolts and mounting
bar. Two of the T50 bolts are visible, the third also attaches the right hand passenger peg and is
accessed by removing the right side passenger foot peg.
11. The right side passenger foot peg is not accessible when system is installed. Relocate right side
passenger foot peg with P/N 16939.
12. Carefully remove the O2 sensors from the stock head pipes.
13. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring
pliers. NOTE: Replace bent or damaged circlips.
14. Check condition of exhaust gaskets and replace if worn or damaged.
Page 3 of 6
D925IN RevC
VANCE & HINES EXHAUST INSTALLATION
1. Install and tighten the bracket (5) using the two lower holes in the frame below the right
passenger footpeg, using two 3/8”x3/4” flange bolts. Install the 3/8-16 x 1 1/2 in. bolt and
spacer in the top hole of the bracket. (Figure 1)
2. Remove header assembly and heat shields from protective packaging. Place each heat shield
on a non-abrasive surface such as blanket or carpet. On chrome, use a felt tip pen and mark
outside edge of each heat shield to show location of mounting clips that hose clamps will loop
through (Figure 2). On black systems mark the outside with a pencil or a piece of tape.
3. Lay header assembly into heat shields and loosely install the #20 hose clamps (supplied)
into mounting clips. NOTE: Screw heads should be accessible when the system is installed on
motorcycle for adjustment purposes (Figure 2). Do not tighten at this time.
4. Apply a small amount of anti-seize compound to the threads of the oxgyen sensors and install
them into the new head pipe. NOTE: 2007 to 2011 models or models using 18mm wideband
oxygen sensors install sensor directly into head pipe. 2012 to 2014 models install supplied 18mm
to 12mm oxygen sensor adapter then install the 12mm oxygen sensors (Grey connector into
front head pipe, Black connector into rear head pipe.) All models not using oxygen sensors
install 18mm plug with copper crush washer.
5. Install circlips and flanges from stock system onto both new head pipes.
6. Using stock flange nuts, carefully install head pipes onto motorcycle. Finger tight only to insure
collar is seated in the exhaust gasket.
7. Slide the T-bolt clamps onto each muffler. Make sure that the nut on the clamp is accessible
when installed on the bike. Install mufflers on the head pipe assembly (V&H stamped logo on
top, no logo on bottom)
8. Attach the muffler bodies to the bracket using the four 1/4-20 x 1/2 flange head bolts.
9. Route O2 sensor wires away from hot areas of the motorcycle. Plug the O2sensor wires back
into the wiring harness: For 2012 & Later, feed wire for the rear O2 sensor (Black) around the
frame and under the seat. Re-install battery, plug the sensor into the stock wiring connector.
Feed connector for the front oxygen sensor (Gray) around the frame and into the holder on
the frame behind rectifier. Plug the sensor into the stock wiring connector. For 2007 to 2011
models, feed wire for the front oxygen sensor around and into the plastic holder on the frame.
Plug the sensor into the stock wiring connector. Snap the plastic holder closed to hold the
connector in place. Install a new nylon cable tie to hold the wires onto the frame in the original
location. Feed connector for the rear oxygen sensor around the frame under the oil tank on
the right hand side. Plug the sensor into the stock wiring connector.
10. On floor board models, tighten the floor board mounting bolts.
11. Be sure to tighten all hardware before starting your motorcycle.
12. After installation and before starting the motorcycle, completely clean pipes and mufflers
with soap and water and a clean soft cloth. NOTE: Any residue, oil, or fingerprints will stain the
chrome when the metal heats up.
Page 4 of 6
D925IN RevC
FIGURE 1
23
25
19
22
FIGURE 2
INSTALLATIO
14
21
Page 5 of 6
D925IN RevC
Emissions Notice:
In California, in order to meet Air Resources Board emissions requirements, certain aftermarket part applications
have been identified as replacements, and others have received ARB Executive Orders. All other emissions
related aftermarket parts are for competition use only. A list of replacement parts and EO parts, and
corresponding fitment is provided at vanceandhines.com/california.
Warranty:
All Vance & Hines products are warranted against defects in material and workmanship for a period of 90 days.
This warranty does not cover discoloration or rust. This warranty shall be limited to the repair or replacement of
the product, which may be proven defective under normal use. Vance & Hines will not warranty any system
that has been abused, misused, improperly installed or modified.
Dealers or distributors are not authorized to make dispositions binding upon Vance & Hines. Vance & Hines will
not be responsible for any labor charges incurred in removing or replacing any system under warranty. A return
authorization number and a copy of the original purchase invoice must accompany all returns. Parts returned
without a return authorization may be refused.
THE NEXT GENERATION OF FUEL MANAGEMENT IS HERE
The Fuelpak FP3 will revolutionize fuel management for all
new Harley-Davidson models now using the HDLAN (CAN Bus)
system. Connecting wirelessly by Bluetooth to iPhone or Android
Smartphones, Fuelpak FP3 uses Flash technology to recalibrate
engine parameters and mapping for Vance & Hines exhaust
systems downloaded from the expansive library of calibrations
developed by Vance & Hines.
•
•
•
•
•
Smartphone App User Interface (iOS and Android)
Recalibrates ECM by Flash Tuning
Autotune Feature for Added Tuning Precision
Displays Live Sensor Data
App Links Direct to Customer Service Site
FITMENT NOTES:
•
•
•
•
FUELPAK FP3 IS COMPATIBLE WITH CAN BUS MODELS ONLY
(TOURING, SOFTAIL, DYNA & SPORTSTER)
FUELPAK FP3 IS NOT COMPATIBLE WITH V-ROD MODELS.
MAPS ARE CURRENTLY AVAILABLE FOR: SPORTSTER, DYNA,
SOFTAIL, TOURING AND TRIKE MODELS.
MAPS FOR 110CI CVO MODELS COMING SOON.
EMISSIONS NOTICE:
FUELPAK IS INTENDED FOR RACING 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
Page 6 of 6
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