more power : less noise
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” or
22mm Combination
wrenches
3/8” Ratchet, extensions
1/2” & 9/16” Sockets
3/16” & 5/16” Allen wrench
T45 & T50 Torx wrenches
READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION
STOCK EXHAUST
SYSTEM REMOVAL
MORE POWER : LESS NOISE
HARLEY-DAVIDSON® SOFTAIL
BIGSHOT STAGGERED BLACK
INSTALLATION INSTRUCTIONS
PART# 47921
1.
2.
3.
4.
NOTE:These instructions are written for late model motorcycles equipped
with O2 sensors. If you are installing these pipes on a bike which is not
equipped with O2 sensors, ignore all instructions which reference them.
Additionally you will need to purchase an O2 sensor block off kit P/N 16925.
However this kit does contain all necessary hardware to install the right side
passenger footpeg on ‘86-’06 model softails (see packing list).
Under the oil tank on the right hand side, locate the rear O2 sensor
connector. Unplug sensor and feed the end of wire through the frame
freeing it from motorcycle. NOTE: Pay attention to wire routing for reinstallation.
Open the plastic cover above the rectifier on front of the frame to gain access
to the front O2 sensor connector. Unplug sensor from harness. Remove cable
tie holding wire to frame and feed the end of the wire through, freeing it
from motorcycle.
On FLSTC, FLSTF, FLSTN and FLSTSC models, loosen the right hand floor
board mounting bolts to gain clearance for exhaust removal and installation.
Loosen the heat shield clamps on both front and rear exhaust pipes.
FIGURE 1
6.
7.
8.
9.
10.
11.
12.
13.
Remove the two mounting nuts from each head pipe, located at the cylinder
head.
Remove the nuts attaching the exhaust mount bracket to the frame.
On FLSTN, FLSTF and FXSTD models, you will need to remove the right side
passenger footpeg and hanger, as this is attached to the exhaust mount
bracket. Replace the passenger foot peg assembly using the 3/8” x 2 1/2”
Allen bolt (supplied).
If equipped, unbolt the carriage bolt and clamp attached to the bracket under
the right side transmission cover.
Remove the entire exhaust system and set it aside.
If equipped, remove the bracket from under the right side transmission cover.
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.
Remove the two lower mounting studs from the frame (Figure 1).
Carefully remove exhaust port flanges and circlips from the stock exhaust
system using snapring pliers. NOTE: Replace bent or damaged circlips. Check
exhaust port gasket condition. Recommended replacement exhaust port
gaskets, Harley part number:17048-98 or 65324-83A.
FIGURE 2
Remove studs
Page 1 of 4
5.
Mark mounting
clip locations
D592IN Rev. 1.0
FIGURE 3
FIGURE 4
FIGURE 5
FIGURE 6
Slide header into
heat shields
VANCE & HINES EXHAUST
SYSTEM INSTALLATION
1.
2.
3.
4.
5.
6.
7.
Install circlips and flanges
Remove header and heat shields from protective packaging. NOTE:
Removal of end cap may be required. Place each heat shield on a nonabrasive surface such as a blanket or carpet. Using a pencil, lightly mark
outside edge of each heat shield to show location of mounting clips
that hose clamps will loop through (Figure 2). NOTE: Pencil marks can
be erased if care is taken not to harm coating.
Slide header into heat shields tail end first, engaging end caps (Figure
3).
Install end caps (if removal was necessary) into tail end of each heat
shield engaging head pipe and heat shield. Align mounting hole with
end cap hole. Install and tighten 1/4”-20 button head screws. NOTE:
Removable thread locking compound is recommended.
Install each hose clamp by feeding tail end of clamps into heat shield
clips. Use #20 hose clamps (supplied) on head pipes and #28 hose
clamps (supplied) on muffler sections. Take note of location of clamp
screw head direction (Figure 2 & 4). Screw head must be accessible
when system is installed on motorcycle for adjustment purposes. Align
end tips evenly and tighten hose clamps.
Apply a small amount of anti-seize compound to the threads of the O2
sensors and install them into the new head pipe. NOTE: Be careful not
to get anti-seize on sensor tip, it may affect sensor function.
Install circlips and flanges from stock system onto the new head pipe
(Figure 5).
Attach mounting bracket (Stamped 330-P)(supplied) using four
5/16“x5/8” flange bolts and two nut plates (supplied). Slide nut plates
inside brackets that are welded to the backside of each muffler (Figure
8.
9.
10.
11.
12.
13.
14.
15.
Install Bracket
6). Leave them loose at this time. Use this procedure for both upper and
lower muffler mounting positions.
Install complete assembly into exhaust ports (rear port first). Use stock
flange nuts, do not tighten at this time. Install exhaust bracket to
motorcycle frame rail using two 3/8”x3/4” flange bolts (supplied). Do
not tighten at this time.
Tighten cylinder port exhaust flange nuts on front and rear cylinders.
Now tighten the 5/16”x5/8” flange bolts (supplied) and the 3/8”x3/4”
flange bolts (supplied) attaching the bracket to the frame.
Feed wire for the front O2 sensor through the frame 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 (supplied) to hold the wires onto frame in
the original location.
Feed connector for the rear O2 sensor through the frame under the
oil tank on the right hand side. Plug the sensor into the stock wiring
connector.
Re-tighten floor board mounting bolts on models so equipped.
Be sure to tighten all hardware before starting motorcycle.
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.
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.
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
Arrows indicate screw head direction
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
D592IN Rev. 1.0
HARLEY-DAVIDSON® SOFTAIL
BIGSHOT STAGGERED BLACK
INSTALLATION INSTRUCTIONS
PART# 47921
Nut plate x 2
1/2” x 3” Allen bolt x 1(for ‘86-‘99 models only)
#20 Hose clamps x 3
ALL PARTS SHOWN ARE ACTUAL SIZE
MORE POWER : LESS NOISE
PACKING LIST
3/8” x 2-1/2” Allen bolt x 1
1/2” Spacer x 1(for ‘86-‘99 models only)
3/8” x 3/4” Flange bolts x 2
3/8” Spacer x 1(for ‘00-’06 models only)
#28 Hose clamps x 4
5/16” x 5/8” Flange bolts x 4
PARTS NOT SHOWN:
330-P Bracket x1
D460FC Head pipe x1
D462HP Front heat shield x1
D463HP Rear heat shield x1
Nylon cable tie x 1
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
D592IN Rev. 1.0
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
D592IN Rev. 1.0
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