power : less noise - Lidor
Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your Vance & Hines exhaust is designed and crafted for maximum performance, a great sound and unbeatable 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.
TOOLS REQUIRED
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.
READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION
STOCK EXHAUST REMOVAL
MORE POWER : LESS NOISE
HARLEY-DAVIDSON® 09-11 XR1200 WIDOW XR 2-1-2 EXHAUST INSTALLATION INSTRUCTIONS PART# 47537
FIGURE 1
1. Find and unplug the O2 sensor wires from the wiring harness. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Remove the clamp bolt from the front head pipe support. NOTE: This bolt will not be used for re-installation. 3. Loosen the two mounting nuts from each head pipe, located at the cylinder head. 4. Remove the muffler assembly by loosening and removing the two bolts that hold the mufflers to the stock hanger mounts. Save the hardware for re-installation. 5. Remove the cylinder head nuts and head pipes, carefully set them aside.
6. 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. 7. Carefully remove the exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: If circlips look bent or twisted, replace them. 8. Remove the belt cover. 9. Remove the head pipe support bracket. Re-install the belt cover and use the supplied washer A465HW as a spacer between the belt cover and the engine case on the lower bolt hole. 10. Inspect the exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. We Recommend Harley Davidson replacement gaskets #17048-98.
FIGURE 2
7-70108 7-70107 Page 1 of 3
D189IN Rev. 1.4
HARLEY-DAVIDSON® 09-11 XR1200 WIDOW XR 2-1-2 EXHAUST INSTALLATION INSTRUCTIONS PART# 47537
2. Apply a small amount of anti-seize compound to the threads of the O2 sensor and install them into the new head pipes. Note: Be careful not to get anti-seize on sensor tip, it may affect sensor function. 3. Install the flanges and circlips removed earlier.
VANCE & HINES EXHAUST INSTALLATION
MORE POWER : LESS NOISE
1. Locate the front head pipe D182FP and rear head pipe D183FP.
4. Install muffler bracket 660-P, refer to figure 1, use the stock hardware for the front mount. The rear mount uses the original bolt with the supplied washer A107HW and lock nut A364HW. The washer goes between the hanger mount and the muffler bracket, refer to figure 2. Do not install the lock nut until the mufflers are mounted as it will be in the way of the muffler mounting hardware. 5. Using the stock flange nuts, carefully install the head pipes into ports beginning with the rear cylinder. Note: Do not tighten the flange nuts completely at this time. 6. Locate the cross over collector D242CLP. Install it to the head pipes, attach with the supplied springs A204SP-P using supplied spring tool. 7. Locate the upper muffler/tail pipe assembly. Slide it on the Collector and install it to the muffler bracket with a dog bone nut plate A195HW and loosely install the two 5/16” flange bolts (supplied). 8. Repeat step 7 with the lower muffler/tail pipe assembly. 9. Align both mufflers and tighten the flange nuts. Install the tail pipe springs to the collector and tighten the cylinder head nuts. Install the lock nut to the rear muffler hanger bolt. 10. Check for adequate clearance between all exhaust system components and those motorcycle accessories prone to heat damage. 11. Be sure to check and tighten all hardware before starting your motorcycle.
EXHAUST CARE - HELPFUL HINTS KEEP YOUR EXHAUST LOOKING NEW 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 3
D189IN Rev. 1.4
HARLEY-DAVIDSON® 09-11 XR1200 WIDOW XR 2-1-2 EXHAUST INSTALLATION INSTRUCTIONS PART# 47537
ALL PARTS SHOWN ARE INCLUDED
MORE POWER : LESS NOISE
PACKING LIST PART NO. D182FP D183FP D242CLP A204SP-P D276RP D275RP 660-P A364HW A107HW A162BEC A123R A501BL A444HW A464HW A195HW A240HW A465HW A110NP 201-SSP-42 A262FG A260SP
47537 INTERNAL BOM DESCRIPTION Front Hd Pipe Assy. Rear Hd Pipe Assy. Collector Assy., MS Spring, BC Tail Pipe/Muffler Assy, Upper Tail Pipe/Muffler Assy, Lower Sprts Muffler Bkt Centerlock Hex Locknut, 5/16"-18 Flat Washer, 5/16" Baffle Endcap, PNC Baffle Core Welded Assy. Baffle Flange 18-8 SS Capscrew 10-32, 3/8" BHCS 1/4"-20 x 1/2", Blk Oxide Dog Bone Nut Plate HHCS, 5/16-18 x 5/8 Flat Washer, 1/4"ID, 9 Ga Name Plate Rivet Baffle Sock Exhaust Spring Puller Tool
BAFFLE CORE WELDED ASSY. A123R
A464HW
47537: 2009-11 WIDOW XR 2-1-2 SYSTEM STOCK EXHAUST: 33 lbs 47537: 22 lbs
FRONT PIPE ASSY. D182FP EXHAUST SPRING PULLER TOOL A260SP REAR PIPE ASSY. D183FP BAFF A262 LE SOC K FG
SPRING A204SP-P
STOCK EXHAUST: 33 lbs 47537: 22 lbs
A444HW
A162BEC
QTY 1 1 1 4 1 1 1 1 1 2 2 2 6 4 2 4 1 2 4 1 1
TAIL PIPE/MUFFLER ASSY. D276RP
COLLECTOR ASSY. D242CLP TAIL PIPE/MUFFLER ASSY. D275RP A465HW 201-SSP-42 A110NP
A240HW A195HW A107HW A364HW
BKT ASSY. 660-P
WARRANTY
Vance & Hines products 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 products 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 3
D189IN Rev. 1.4
TOOLS REQUIRED
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.
READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION
STOCK EXHAUST REMOVAL
MORE POWER : LESS NOISE
HARLEY-DAVIDSON® 09-11 XR1200 WIDOW XR 2-1-2 EXHAUST INSTALLATION INSTRUCTIONS PART# 47537
FIGURE 1
1. Find and unplug the O2 sensor wires from the wiring harness. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Remove the clamp bolt from the front head pipe support. NOTE: This bolt will not be used for re-installation. 3. Loosen the two mounting nuts from each head pipe, located at the cylinder head. 4. Remove the muffler assembly by loosening and removing the two bolts that hold the mufflers to the stock hanger mounts. Save the hardware for re-installation. 5. Remove the cylinder head nuts and head pipes, carefully set them aside.
6. 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. 7. Carefully remove the exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: If circlips look bent or twisted, replace them. 8. Remove the belt cover. 9. Remove the head pipe support bracket. Re-install the belt cover and use the supplied washer A465HW as a spacer between the belt cover and the engine case on the lower bolt hole. 10. Inspect the exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. We Recommend Harley Davidson replacement gaskets #17048-98.
FIGURE 2
7-70108 7-70107 Page 1 of 3
D189IN Rev. 1.4
HARLEY-DAVIDSON® 09-11 XR1200 WIDOW XR 2-1-2 EXHAUST INSTALLATION INSTRUCTIONS PART# 47537
2. Apply a small amount of anti-seize compound to the threads of the O2 sensor and install them into the new head pipes. Note: Be careful not to get anti-seize on sensor tip, it may affect sensor function. 3. Install the flanges and circlips removed earlier.
VANCE & HINES EXHAUST INSTALLATION
MORE POWER : LESS NOISE
1. Locate the front head pipe D182FP and rear head pipe D183FP.
4. Install muffler bracket 660-P, refer to figure 1, use the stock hardware for the front mount. The rear mount uses the original bolt with the supplied washer A107HW and lock nut A364HW. The washer goes between the hanger mount and the muffler bracket, refer to figure 2. Do not install the lock nut until the mufflers are mounted as it will be in the way of the muffler mounting hardware. 5. Using the stock flange nuts, carefully install the head pipes into ports beginning with the rear cylinder. Note: Do not tighten the flange nuts completely at this time. 6. Locate the cross over collector D242CLP. Install it to the head pipes, attach with the supplied springs A204SP-P using supplied spring tool. 7. Locate the upper muffler/tail pipe assembly. Slide it on the Collector and install it to the muffler bracket with a dog bone nut plate A195HW and loosely install the two 5/16” flange bolts (supplied). 8. Repeat step 7 with the lower muffler/tail pipe assembly. 9. Align both mufflers and tighten the flange nuts. Install the tail pipe springs to the collector and tighten the cylinder head nuts. Install the lock nut to the rear muffler hanger bolt. 10. Check for adequate clearance between all exhaust system components and those motorcycle accessories prone to heat damage. 11. Be sure to check and tighten all hardware before starting your motorcycle.
EXHAUST CARE - HELPFUL HINTS KEEP YOUR EXHAUST LOOKING NEW 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 3
D189IN Rev. 1.4
HARLEY-DAVIDSON® 09-11 XR1200 WIDOW XR 2-1-2 EXHAUST INSTALLATION INSTRUCTIONS PART# 47537
ALL PARTS SHOWN ARE INCLUDED
MORE POWER : LESS NOISE
PACKING LIST PART NO. D182FP D183FP D242CLP A204SP-P D276RP D275RP 660-P A364HW A107HW A162BEC A123R A501BL A444HW A464HW A195HW A240HW A465HW A110NP 201-SSP-42 A262FG A260SP
47537 INTERNAL BOM DESCRIPTION Front Hd Pipe Assy. Rear Hd Pipe Assy. Collector Assy., MS Spring, BC Tail Pipe/Muffler Assy, Upper Tail Pipe/Muffler Assy, Lower Sprts Muffler Bkt Centerlock Hex Locknut, 5/16"-18 Flat Washer, 5/16" Baffle Endcap, PNC Baffle Core Welded Assy. Baffle Flange 18-8 SS Capscrew 10-32, 3/8" BHCS 1/4"-20 x 1/2", Blk Oxide Dog Bone Nut Plate HHCS, 5/16-18 x 5/8 Flat Washer, 1/4"ID, 9 Ga Name Plate Rivet Baffle Sock Exhaust Spring Puller Tool
BAFFLE CORE WELDED ASSY. A123R
A464HW
47537: 2009-11 WIDOW XR 2-1-2 SYSTEM STOCK EXHAUST: 33 lbs 47537: 22 lbs
FRONT PIPE ASSY. D182FP EXHAUST SPRING PULLER TOOL A260SP REAR PIPE ASSY. D183FP BAFF A262 LE SOC K FG
SPRING A204SP-P
STOCK EXHAUST: 33 lbs 47537: 22 lbs
A444HW
A162BEC
QTY 1 1 1 4 1 1 1 1 1 2 2 2 6 4 2 4 1 2 4 1 1
TAIL PIPE/MUFFLER ASSY. D276RP
COLLECTOR ASSY. D242CLP TAIL PIPE/MUFFLER ASSY. D275RP A465HW 201-SSP-42 A110NP
A240HW A195HW A107HW A364HW
BKT ASSY. 660-P
WARRANTY
Vance & Hines products 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 products 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 3
D189IN Rev. 1.4
