KAWASAKI VULCAN 1500 LONGSHOT EXHAUST SYSTEM
KAWASAKI VULCAN
1500 LONGSHOT
EXHAUST SYSTEM
Part #18387
CONGRATULATIONS! You have purchased the finest exhaust system available for your motorcycle.
Your VANCE & HINES exhaust system is designed for today's rider, a rider who needs maximum
performance, great styling and a perfect fit. Please follow the installation instructions below and if
you have any questions, feel free to call our technical help line (562) 926-5291.
REMOVING THE STOCK EXHAUST SYSTEM
1. Remove the mufflers by loosening the pinch clamps on the front of each muffler.
2. Remove the muffler mounting bolt from the right side passenger footrest, slide the mufflers off
and set them aside. Note: Save the mounting bolt, it will be reused for installation.
3. Loosen the pinch clamp on both front and rear head pipes, they’re located at the resonance
chamber (the black box where the pipes meet).
4. Remove the two acorn nuts that mount the head pipe to the cylinder head. Remove the two piece
header flange and set it aside.
5. Remove the front head pipe by rotating it down and pull it out of the resonance chamber.
6. Remove the two acorn nuts and flange from the rear head pipe. Remove the two bolts from
either side of the resonance chamber and lower rear pipe and resonance chamber down and out
and set it aside.
INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM
1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to
their condition, replace them.
2. Slide the supplied flanges over the front and rear head pipes
3. Install the heat shield to the front head pipe using the three hose clamps (supplied). Unscrew all
of the hose clamps (supplied) until they are completely loose. Feed the tail end of the hose
clamp into the clips on the inside of both heat shields. Place the front head pipe into the heat
shield, wrap the hose clamp around the head pipe and give the screw three to four turns, leaving
heat shield loose on the head pipe. Repeat this step with the rear head pipe/heat shield.
Note: The screw end of the hose clamp should be accessible but not visible when pipe is
mounted on the bike. Leave them loose at this time.
4. Install the rear head pipe, with the heat shield attached to the rear cylinder using the stock nuts.
Leave them loose at this time.
5. Install the front head pipe, with the heat shield attached, to the front cylinder using the stock
nuts, leave them loose at this time.
6. Using the stock hardware, mount the VHR muffler bracket to the stock muffler mounting point,
with the four hole portion bent towards the center of the motorcycle. (refer to fig. 1)
7. Slide a chrome muffler clamp (supplied) onto the inlet end of each muffler. Install a 5/16” x 1
1/4” bolt with a flat washer on either side of the clamp followed by a lock nut (supplied). Do this
to each muffler but leave the clamp loose at this time.
8. Slip one muffler onto the rear head pipe. Slide one dog bone shaped nut plate under the bracket
that is welded to the backside of the muffler and attach the muffler to the mounting bracket
using two of the 5/16” flange head bolts (supplied), but leave them loose at this time.
9. Repeat step #9 with the front muffler.
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K380IN Rev 1.1
10. Adjust the heat shields and mufflers so they match flush where the the two parts meet each
other. Refer to figure #2.
11. Align the mufflers so they’re parallel when viewing from the right side of the bike, and tighten the
5/16” flange bolts on both mufflers.
12. Tighten the two nuts on both front and rear head pipes.
13. Tighten the two muffler clamps.
14. Rotate the hose clamps on both heat shields so they’re accessible with a screw driver and
tighten each of them evenly.
15. Be sure to tighten all hardware before starting your motorcycle.
RE-JETTING INSTRUCTIONS
Re-jetting the carburetors will result in realizing the "full" potential of this performance exhaust
system. Vance & Hines offers a jet kit, call for your application.
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, (center stand, oil filter, oil
pan etc.) ground and cornering clearance may not be improved and in some cases may be reduced.
Be sure to follow proper installation instructions.
WARNING!
VANCE & HINES DOES NOT WARRANTY ANY CHROME
PRODUCTS AGAINST DISCOLORATION.
VIEW FROM RIGHT SIDE OF
MOTORCYCLE
VIEW FROM REAR
OF MOTORCYCLE
FIG. 1
BE SURE THAT THE HEAT
SHIELD AND THE MUFFLER
MATCH FLUSH WITH NO GAP.
HEAT SHIELD
MUFFLER
FIG. 2
VIEW FROM RIGHT HAND SIDE OF MOTORCYCLE
For information about other Vance and Hines products visit our web site at www.vanceandhines.com
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K380IN Rev 1.1
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K380IN Rev 1.1
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