INTRUDER 1400
SLIP-ON EXHAUST
SYSTEM
Part #’s 18261 & 19261
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 fitting system.
REMOVING THE STOCK EXHAUST SYSTEM
1. Loosen the mounting bolt and pinch clamp on both left and right hand mufflers.
2. Loosen the clamp on the crossover tube, located between the two mufflers.
3. Remove the two nuts that mount the front head pipe flange to the cylinder head.
4. Remove the two nuts that mount the rear head pipe flange to the cylinder head.
5. Remove the head pipes using a twisting motion to break the seal at the muffler and to clear the
cylinder head. Note: If the exhaust coupler gaskets did not remain in the mufflers, remove them
from the head pipes at this time. These coupler gaskets will not be reused in your new exhaust
system.
6. Remove the mounting bolt from the left hand muffler. Remove the muffler, again using a twisting
motion to seperate the crossover tube and set the muffler aside. (Save the stock mounting
hardware for reuse).
7. Repeat step #6 on the the right hand muffler. Set the muffler 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. Reinstall the stock head pipes to the engine. Note: Leave the flange nuts loose at this time.
3. Remove the mufflers from their boxes. There are a left and right hand muffler in this system. To
define the difference between the left and right mufflers, check the bracket that is welded to the
back side of the muffler. Each muffler is stamped with it’s own part number. Part # D500 is the
RIGHT muffler and Part # D550 is the LEFT muffler.
4. Install a three hole mounting bracket to each of the mufflers. Slide one dog bone shaped nut
plate under the bracket that is welded to the backside of each muffler. Attach the mounting
bracket using two of the 5/16 flange head bolts (supplied), leave them loose at this time.
Note: Each muffler bracket has a number stamped on it, #179 bracket is for the left hand
muffler and #180 is for the right hand muffler. When the brackets are mounted correctly, the end
of the bracket with the single hole should point to the inlet end (small end) of the muffler. Refer
to figure 1.
5. Remove the single bend exhaust tubes from the box. Install a pinch clamp (supplied) onto the
notched end of each tube.
6. Slip the notched end of each tube onto the stock head pipes (the longer of the two tubes mounts
on the left side) with the angle in the tube pointing up and outwards. Tighten the clamp bolts just
enough so you are able to rotate the tubes.
7. Install one muffler clamp over the front (notched end) of each muffler.
8. Slip the appropriate muffler onto the matching exhaust tube. Rotate the exhaust tubes until you
can line up the muffler mounting hole with the hole on the motorcycle. Install the stock mounting
bolts and nuts and leave them loose.
Page 1 of 2 S380IN Rev.2.0
9. With the system in place, you must position the muffler outlets evenly when viewing from the
rear of the motorcycle. To accomplish this, have someone hold the motorcycle upright and on
level ground, rotate the exhaust tubes a small amount in either direction so the muffler outlets
are an equal distance from the ground.
10. Tighten all mounting hardware and clamp bolts.
11. The muffler clamps should be rotated down and in as far as possible without touching the frame.
12. Check all alignment and clearances one more time.
13. 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. Note: The screw end of the
hose clamp should be accessible, but not visible when pipe is mounted on the motorcycle.
14. Install the heat shields onto the exhaust tubes, the heat shields will snap into place covering the
muffler clamps.
15. Position the heat shield and/or muffler so the weld on the muffler is covered. Tighten the hose
clamps on the heat shields.
16. Wipe any fingerprints off the exhaust system before starting the motorcycle!
17. 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 improved and in some cases may be reduced. Be
sure to follow proper installation instructions.
D550 D500
FIGURE 1
#179 #180
VIEW FROM REAR OF
MOTORCYCLE
Page 2 of 2 S380IN Rev.2.0
