INSTALLATION INSTRUCTIONS:

HARLEY-DAVIDSON DYNA
STAINLESS 2-1
PART# 27625
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.
7 6 5 4 3 2

11 2

PARTS LIST
NO. Part No. Description Qty. NO. Part No. Description Qty.
1 D374RB-S Muffler can assembly 1 9 A527HW M18 O2 bung plug 2
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF VA
DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR ANY OTHER PURPOSE, UNLES
UNLESS OTHERWISE SPECIFIED NAME DATE
SANT
2 D1122FB Front head pipe assembly 1 10 A283HW 3/8-16 low profile SHCS 2
CAD
INTERPRET DIMENSIONS
AND TOLERANCES DIMENSIONS ARE INCHES J. ARCEO 7/2/2018 BR
PER ANSI Y14.5M TOLERANCES ARE: DRAWN www.v
FRACTIONAL: 1/16" J. ARCEO 7/2/2018

3 D1123FB Rear head pipe assembly 1 11 1169-P Mount bracket 1

THIRD ANGLE PROJECTION ANGULAR: 2 CHECKED PROJECT
X.X 0.030"
S. GUTIERREZ 7/20/2018
X.XX 0.015"
X.XXX 0.010" APPROVED

12 A527HW-P Floor board spacer 1

TITLE
4 A240HW 5/16-18 X 5/8” FHS 2
M. BERMUDEZ 9/7/2018
MATERIAL
SEE INDIV. DWGS SIZE PA

5 A195HW Dogbone nut plate 1 13 A107HW 5/16” SAEFINISH

flat washer 3 B
BRUSHED WT. 10.7

7 6 A644ST 6 18-12mm O2 adaptor

5 2 14 4 A121HW 18mm x 24mm
3 washer 2 2
7 A115SP Dirt Sport Spring 2 15 A345HW 5/16-18 X 1 1/2” bolt 3
8 A260SP Spring puller 1 16 71001 6IN O2 extension lead 1

Page 1 of 7 D914IN RevA

 HARDWARE
15
7
16 8

10
4

12 14 9
13

TOOLS REQUIRED

THE INFORMATION CONTAINED IN THIS DRAWING IS

5/16” Nut Driver

DISCLOSED TO OTHERS FOR MANUFACTURE OR FOR A

Flat blade Screwdriver UNLESS OTHERWISE SPECIFIED

INTERPRET DIMENSIONS
CAD
NAM

AND TOLERANCES DIMENSIONS ARE INCHES J. ARC

PER ANSI Y14.5M TOLERANCES ARE: DRAWN
FRACTIONAL: 1/16" J. ARC
THIRD ANGLE PROJECTION ANGULAR: 2 CHECKED
X.X 0.030"
S. GUTIE
X.XX 0.015"
X.XXX 0.010" APPROVED
M. BERM
MATERIAL
SEE INDIV. DWGS

Combination Wrench: 3/8” Ratchet, extensions

FINISH
BRUSHED
1/2”,
6 7/8” or 22mm & 5 4 1/2” & 19mm Sockets 3
14mm 9/16” Deep Socket

Allen Wrenches: 3/16”, Snap ring Pliers

1/4”, 3/8”

Page 2 of 7 D914N RevA

 STOCK EXHAUST SYSTEM REMOVAL
1. For O2 sensor equipped models (06-17), remove seat to gain access to rear oxygen sensor
connector. Unplug sensor and feed end of wire through frame to free it from motorcycle. NOTE:
Pay attention to wire routing for re-installation.
2. For 2006 to 2011 models, remove two bolts holding rectifier onto front of frame (near front tire).
Open plastic cover to gain access to front oxygen sensor connector. Unplug sensor from harness
and feed end of wire through to free it from motorcycle. For 2012 to later models, the connector
is located under the rectifier at the front of the motorcycle.
3. Loosen the heat shield clamps on both the front and the rear head pipes.
4. Remove two cylinder exhaust port flange nuts from each head pipe, located at the cylinder
head.
5. If equipped, remove the front head pipe clamp carriage bolt.
6. Remove the bolt that attaches the mufflers to the frame mounting bar.
7. Remove the complete exhaust system and set aside (assistance may be required).
8. Remove the stock mounting bar and the studs in the transmission cover.
9. Position the muffler support bracket over mounting location to determine which bolts to remove
(Figure 1). Install removed bolt in the top hole left vacant by the new bracket.
10. Carefully remove the flanges and circlips from the stock exhaust system using snap ring pliers.
NOTE: Replace bent or damaged circlips. (Recommended replacement exhaust port gaskets,
HD #65324-83B).
11. Carefully remove stock oxygen sensors. They will be re-used on the new system.

VANCE & HINES EXHAUST INSTALLATION

1. Attach the muffler support bracket to transmission and tighten to 12-15ft/lb. Torque using three
5/16” x 1 1/2” hex head bolts and washers (items 13 & 15) (Figure 1).
2. Install the mid control spacer (item 12) on motorcycles equipped with mid controls using 2x 3/8-
16 low profile SHCS (item 10) (Figure 2).
3. Remove head pipes from protective packaging. Apply a small amount of anti-seize compound
to the threads of the oxygen sensors and install them into the new head pipe. NOTE: For 2006
to 2011 models or models using 18mm wideband oxygen sensors, install sensor directly into
head pipe. For 2012 to later models, install supplied 18mm to 12mm oxygen sensor adapter
then install 12mm oxygen sensors (Grey connector into front head pipe, Black connector into
rear head pipe.) For all models not using oxygen sensors, install 18mm plug with copper crush
washer.
4. Install exhaust port flanges and circlips (from stock system) onto head pipes.
5. Using stock flange nuts, carefully install head pipes into exhaust ports, starting with the rear
cylinder. Assistance may be required. NOTE: Do not tighten at this time.
6. Install muffler assembly onto head pipes. Attach muffler assembly to installed bracket and
secure with 5/16-18 flange bolts & dog bone nut plate (supplied).
7. Install springs using supplied spring puller. There should be about a 2” gap between the spring
tabs (Figure 3).
8. Tighten exhaust port flange nuts and 5/16” flange head bolts at the bracket.

Page 3 of 7 D914IN RevA

 VANCE & HINES EXHAUST INSTALLATION CONTINUED
9. Feed wire for front oxygen sensor through frame and into plastic holder on frame. Plug sensor
into stock wiring connector. Snap plastic holder closed to hold connector in place.
10. For 2006 to 2011 models, put the toothed edge of the wiring holder into the slot in frame.
Re-install rectifier so that it fits under tooth of wiring holder, keeping it in place in the frame.
Tighten both the bolts.
11. Install a new cable tie (supplied) to hold wires in original location.
12. Feed connector for rear oxygen sensor through frame and into the under seat compartment.
Plug sensor into stock wiring connector. For 2006 to 2011 models, use supplied O2 extension
lead (item 16).
13. Reinstall the seat.
14. Check for adequate clearance between all exhaust system components and motorcycle
accessories prone to heat damage. NOTE: On some mid control models, rear brake pedal
height may need to be adjusted to achieve clearance to rear head pipe when brake is
engaged. Use the following steps to adjust brake pedal height.
1. Remove muffler and front head pipe.
2. Remove bolts securing the brake pedal bracket to the frame.
3. Remove pin and disengage brake rod from brake pedal.
4. Loosen the brake rod jam nut next to the master cylinder.
5. Rotate the brake rod counter clockwise lengthening the brake rod 3-5 turns.
6. Tighten the jam nut securely.
7. If necessary, ensure the drain hole in the rubber boot is positioned to the bottom.
8. Re-install brake pedal bracket to the frame using spacer and low profile allen screws.
9. Re-install front head pipe and muffler then check brake pedal clearance.
10. If necessary, repeat adjustment until brake pedal does not contact rear head pipe
when the brake is applied.
• Caution: When adjusting brake control rod, never allow more than six threads to be
exposed between control rod and jam nut. If six (6) threads are visible past the jam nut,
there is insufficient break rod thread engagement into the master cylinder push rod.
This could cause the brake rod to separate from the push rod, making the rear brake
inoperative.
15. Be sure to tighten all hardware before starting your motorcycle.

EXHAUST CARE (STAINLESS)

1. When installing a new set of stainless pipes, make sure your hands are clean and free of
oil. After installation, thoroughly clean pipes with a soft cloth and cleaning solvent that will
leave no residue (glass cleaner, alcohol, acetone, etc...) before starting the motorcycle.
2. It is considered normal for stainless steel exhaust systems to discolor due to heat.
3. High performance engine tuning utilizing a dyno will likely result in severe discoloration.
4. Avoid long periods of idling as this can cause discoloration. Intake leaks can cause the
engine to run lean and overheat and this could lead to discoloration.
5. 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.

D914IN RevA
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FIGURE 1

FIGURE 2

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 FIGURE 3

2.0”

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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

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