Installation

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
#3 Phillips Head
Snapring pliers
5/16” Nutdriver
1/2”, 9/16” &
14mm Combination
wrenches
3/16” & 5/16” Allen &
T45 & T50 Torx wrench
3/8” Ratchet, extensions
19mm, 1/2” Sockets
3/4”, 9/16” Deep Socket
READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION
1.
STOCK EXHAUST
SYSTEM REMOVAL
MORE POWER : LESS NOISE
HARLEY-DAVIDSON® SOFTAIL
SUPER RADIUS 2-2 BLACK
INSTALLATION INSTRUCTIONS
PART# 46051
2.
3.
4. 5
6.
7.
On FLSTC, FLSTF, and FLSTN, loosen the right hand floor board mounting bolts to gain clearance for
exhaust removal and installation.
On FLSTF, FXS and FLSTN and FXSTD, you will need to remove the right side passenger footpeg and
hanger, as this is attached to the exhaust mount bracket. Leave the footpeg and hanger off, additional
reinstallation instructions to follow.
Unbolt the carriage bolt and clamp attached to the bracket located under the right side transmission
cover.
Loosen crossover pipe clamp located between front and rear head pipes and.
Loosen the heat shield clamps on both front and rear exhaust pipes.
Remove the two mounting nuts from each head pipe.
Remove the nuts attaching the exhaust mounting bracket to the frame.
O2 SENSOR EQUIPPED MODELS (2007-PRESENT)
8.
9.
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 reinstallation. 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.
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
FIGURE 1
Install Bracket
FIGURE 2
the plastic cover above the rectifier to gain access to the sensor plug, cut the cable ties holding the
sensor wire to frame.
10. Remove the exhaust system and set it aside. Assistance may be required,.
11. Carefully remove the O2 sensors from the stock head pipes.
12. 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. Re-install the right passenger foot peg
using the 1/2”x3” capscrew with the 1 5/8” spacer and 1/4” bolt to secure fender.
13. 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 foot peg. Re-install the foot peg using the 3/8”x2 1/2” capscrew with the 3/4” spacer.
14. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers.
NOTE: Replace bent or damaged circlips.
15. Check condition of exhaust gaskets and replace if worn or damaged.
FIGURE 3
Install footpeg offset firmly
against frame casting
FIGURE 4
Install hose
clamps
Arrows indicate screw head direction direction
Mark mounting clip
locations
Page 1 of 4
D871IN Rev.1.1
FIGURE 5
FIGURE 6
1/4” SET BACK
1.
VANCE & HINES EXHAUST
SYSTEM INSTALLATION
MORE POWER : LESS NOISE
Install circlip and flanges
For 2000 and later models replace the passenger footpeg and hanger using the
supplied footpeg offset bracket, 3/8” x 1-1/4” flange head bolt and 3/8” x 2-1/2”
Allen bolt (figure 2). NOTE: The threaded insert on the footpeg offset bracket
should rest firmly against the frame casting, be sure to tighten this bolt firmly
and check from time to time. Repeat for left side. For 1999 and older models
passenger footpegs can not be installed.
2. Remove header assembly and heat shields from protective packaging. Place
each heat shield on a non-abrasive surface such as 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).
3. Lay header assembly into heat shields and loosely install the #20 hose clamps
(supplied) into mounting clips (Figure 3). NOTE: Screw heads should be
accessible when the system is installed on motorcycle for adjustment purposes
(Figure 4). 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 the install 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
(Figure 5).
6. Install backet (734-P) onto header assembly using the nut plate and 5/16” x 5/8”
flange bolts (supplied). Do not tighten at this time.
7. Using stock flange nuts, carefully install head pipes onto motorcycle. Finger tight
only to insure collar is seated in the exhaust gasket.
8. Attach the bracket to the frame using the 3/8” x 3/4” bolts. (Figure 1)
9. Beginning with 3/8” x 5/16” bolts on the bracket, tighten them to bring the
braket flush to the frame and chassis, then tightn the stock header flange nuts
to fully seat the collars in the gaskets. Fully tighten all bolts and nuts.
10. Install muffler heat shields on the header assembly (V&H stamped logo on
top, no logo on bottom) using the #36 hose clamp in rear location and #28
hose clamp in the forward position. Adjust muffler heat shields for a 1/4” gap
between the heat shield and exhaust tip (Figure 5) and tighten all hose clamps.
11. Route O2 sensor wires away from hot areas of the motorcycle. Plug the O2
sensor 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.
12. On floor board models, tighten the floor board mounting bolts.
13. Be sure to tighten all hardware before starting your motorcycle.
14. 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.
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. Avoid long periods of idling as this can cause discoloration.
3. Intake leaks can cause the engine to run lean and overheat, this could lead to
discoloration.
4. 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.
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
D871IN Rev.1.1
HARLEY-DAVIDSON® SOFTAIL
SUPER RADIUS 2-2 BLACK
INSTALLATION INSTRUCTIONS
PART# 46051
Nut plate x 2
ALL PARTS SHOWN ARE ACTUAL SIZE
MORE POWER : LESS NOISE
PACKING LIST
#28 Hose clamps x 2
#20 Hose clamps x 5
.75” x .75” Spacer
#36 Hose clamps x 2
5/16” x 5/8” Flange bolts x 4
3/8” x 3/4” Flange bolts x 2
3/8” x 2-1/2” Allen bolt x 1
3/8” x 1 1/4” Flange bolts x 2
PARTS NOT SHOWN:
436-PFootpeg bracketx2
734-PBracket x1
D642FC Front head pipe x1
D667HP Front heat shield x1
D668HP Rear heat shield x1
D650HP Front muffler heat shield x1
D651HP 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
D871IN Rev.1.1
FUEL MANAGEMENT
MORE POWER : LESS NOISE
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) 921-7461 / TECHNICAL: (562) 926-5291 / FAX: (562) 802-0110
VANCEANDHINES.COM
Page 4 of 4
D871IN Rev.1.1
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