HARLEY-DAVIDSON® V-ROD MUSCLE

2 INTO 1 COMPETITION SERIES EXHAUST SYSTEM

INSTALLATION INSTRUCTIONS
PART# 75-116-9

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
MORE POWER : LESS NOISE

and if you need any assistance please contact our technical support line
(562) 921-7461.

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.
Flat blade Screwdriver Snapring pliers

5/16” Nut driver

REQUIRED
3/8” Ratchet, Extensions

TOOLS
Wrenches 9/16”,
7/16”, 1/2”, 13, 14 & 22mm
Combination Wrenches 7/16”, 1/2,” 5/16”
Sockets 8, 10, 12, 13
Allen Wrenches,5 & 6mm & 15mm
T-25 Torx

READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION

Note: (Make sure key switch and handlebar run switch is in off position) 5. Remove front cylinder pipe by loosening exhaust flange nuts. Carefully
Attention: This exhaust system is for racing purposes only. Must use early model remove pipe from bike.
#65109-01 exhaust gaskets and NOT the Muscle #64971-09 exhaust gaskets. 6. Remove the passenger peg from the original mounts using a snapring
pliers, be careful to not overexpand the circlip.
STOCK EXHAUST SYSTEM REMOVAL 7. Carefully remove the stock exhaust flanges and circlips from the front and
STOCK EXHAUST REMOVAL

1. To remove the stock mufflers loosen and remove the two nuts holding the rear head pipes. (If using a Power Commander install O2 eliminator now
muffler to the passenger foot-peg. Remove foot-peg and stud assembly and reinstall cowl panel.)
from the rubber grommets and set aside. Loosen and remove the single nut If the exhaust circlips are bent or twisted they should be replaced, Harley-
towards rear of the muffler which holds the muffler to the round bar section Davidson part number #65045-01
of the foot-peg/exhaust bracket. Loosen the muffler clamp that holds the Replace the stock exhaust gaskets with Harley-Davidson part
muffler to the head pipe. Loosen all heat shield clamps and remove heat number #65109-01
shields from pipes. Pull muffler away from head pipe and set aside. Repeat COMPETITION SERIES EXHAUST SYSTEM INSTALLATION
for both sides. 8. Locate left foot-peg mount (with spacer) D236MB install using one M8 x
2. Remove Foot-peg/exhaust bracket by removing the three allen bolts holding 25mm socket head cap screw and a M8 x 50mm socket head cap screw
the bracket to the frame, set bracket aside. Repeat for both sides. supplied. Use a medium strength loctite® and torque to 18 ft/lbs refer to
3. Remove rear pipe by removing the three allen screws that hold on the (Figure 1), repeat for the right side refer to (Figure 2).
pulley/belt cover to gain access to exhaust flange nuts. Loosen and remove 9. Reinstall the original passenger pegs removed earlier on to the new foot-
the two exhaust flange nuts. Loosen the crossover pipe clamp. Disconnect peg mounts.
the O2 sensor wire by following the wire to the connector underneath the 10. Identify front head pipe D229FP. Install the stock flange and circlip, install
seat. Unplug the connector and pull wire free from all clamps. Remove head pipe leaving the flange nuts hand tight.
pipe and set aside. 11. Repeat the above step for the rear head pipe D230FP.
4. Disconnect front O2 sensor plug by removing the allen screw on bottom of 12. Install megaphone mounting bracket 676-P (with grommet) to the
the left side radiator cowl, pull downward at the bottom of the cowl to free megaphone with two 5/16 flange bolts and dog bone nut plate supplied.
from pin and then lift at the top of the cowl to free from another pin, set cowl First slide the dog bone nut plate inside the bracket welded to the back of
aside. Disconnect Plug and remember the wire routing for re-installation. the megaphone then attach and align bracket refer to (Figure 2), leave the
Note: Do not use excessive force on the cowl panel or damage may result. bolts hand tight at this time.
Page 1 of 3 D236IN Rev. 1.0
 HARLEY-DAVIDSON® V-ROD MUSCLE
2 INTO 1 COMPETITION SERIES EXHAUST SYSTEM
INSTALLATION INSTRUCTIONS
PART# 75-116-9

13. Slip the megaphone/collector assembly onto the head pipes, secure the four to (Figure 4). On 2012 models the sensor will remain in the original location,
EXHAUST INSTALLATION

springs supplied using the spring puller tool. Align megaphone mounting refer to (Figure 6 & 7).
bracket install using the remaining M8 x 25mm socket head cap screw and 18. Make sure the oil line is not touching the front head pipe. If necessary,
loosen the ties and rotate the oil line away from head pipe, re-tie the oil line
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a flat washer on each side of the grommet use a medium strength loctite®
VANCE & HINES

and torque to 18 ft/lbs. to the fan mount refer to (Figure 5).

14. Rotate the exhaust so there is adequate clearance in all places. Clearance 19. After installation and before starting motorcycle, completely clean pipes
at the clutch cover should be at least 1/4”. and mufflers with cleaning soapy water and a soft cloth that will not leave
15. Tighten the cylinder head flange nuts for both the front and rear head pipes. a residue. NOTE: Any residue, oil or fingerprints will stain the the exhaust
Tighten the two 5/16 flange bolts supporting the megaphone mounting when the metal heats up..
bracket. 20. You are now ready to start the motorcycle. (Quiet
16. If using a Power Commander with O2 eliminators tighten the O2 plugs on Baffle 7-60093 available - sold sepretly)
the front and rear head pipes. Note: After initial ride it is recommended to re-torque the baffle screw to 8-10 lb.
17. If using a fuel management system that requires the stock O2 sensors using a 5/32” allen wrench and retighten the cylinder head flange nuts.
remove them from the stock head pipes and install them on new head
For best results, we recommend fuel injection mapping for your new
pipes. Due to O2 sensors location it will be necessary to swap front and
combination using a Fuelpak or Power Commander. Settings for the
rear O2 sensors. Reroute O2 sensor with longer wire to the front cylinder
Fuelpak and some Power Commander maps are available on our website at
refer to (Figure 3) and O2 sensor with shorter wire to the rear cylinder refer www.vanceandhines.com
FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4

FIGURE 5 FIGURE 6 FIGURE 7

EXHAUST CARE - HELPFUL HINTS KEEP YOUR EXHAUST LOOKING NEW

1. When installing a new set of Stainless Steel pipes, make sure your hands are clean and free of oil. 2. Avoid long periods of idling as this can cause discoloration.
After installation, thoroughly clean pipes with warm soapy water and a soft cloth. Dry with clean 3. Intake leaks can cause the engine to run lean and overheat, this could lead to discoloration.
towel to remove any residue before starting the motorcycle. Do NOT use anything abrasive to 4. Make sure there are no exhaust leaks at the junction of the exhaust pipes and cylinder head.
clean pipes. 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 D236IN Rev. 1.0
 HARLEY-DAVIDSON® V-ROD MUSCLE
2 INTO 1 COMPETITION SERIES EXHAUST SYSTEM
INSTALLATION INSTRUCTIONS
PART# 75-116-9
PACKING LIST
75-116-9 PARTS LIST
DESCRIPTION
75-116-9 V-ROD MUSCLE 2:1 COMPETITION SERIES
PART NO. QTY.
D229FP Front Pipe Assy. BCC
D230FP Rear Pipe Assy. BCC
A213HW
A121HW
O² Sensor Plug 18mm, Steel
Washer, 24x18x1mm, Copper
2
2
BCC EXHAUST SYSTEM
MORE POWER : LESS NOISE

A216HW O² Sensor Plug 12mm, Steel 2

A127HW Washer, 16x12x1mm, Copper 2
D3315RP Megaphone Assy. 1
676-P Meg. Mounting Bracket (A) 1
A204SP Spring 2
A195HW Dog Bone Nut Plate 1 FRONT PIPE ASSY.
A240HW HHCS, 5/16-18 x 5/8 2 EXHAUST SPRING D229FP
A128BEC Comp. Baffle End Cap, TVD-DPD 1 PULLER TOOL
A127R Baffle Welded Assy. - A260SP
A444HW 18-8 SS Capscrew 10-32, 3/8" 3
A445HW BHCS 1/4"-20 x 5/8", Zinc 1 REAR PIPE ASSY.
A112HW Flat Washer Zinc, 1/4" 2 D230FP
A115HW Lock Washer Zinc, 1/4" 2
A235HW BHCS 1/4"-20 x 1/2", Zinc 1
A507HW Rubber Grommet MS 1
A428HW Bolt, M8x1.25x25mm 4
22683 Washer, 5/16x13/16x.055 Thk 2 O² SENSOR
ALL PARTS SHOWN ARE INCLUDED

C906 Exhaust Mount Isolator Spacer 1 PLUG A216HW

D235MB Muscle Rt Footpeg Bracket 1
D236MB Muscle Lt Footpeg Bracket 1 WASHER
A210HW Bolt, M8 x 1.25 x 50mm 1 A127HW
A260SP Exhaust Spring Puller 1
A267FG Baffle Sock 1
O² SENSOR
PLUG A213HW
STOCK EXHAUST: 46 lbs
75-116-9: 8 lbs
WASHER
A121HW
A507HW

A240HW BAFFLE SOCK

22683 C906 SPRING A267FG
A204SP
A428HW
A195HW

676-P
As of Jan 15, 2012 Logo
is laser etched on
megaphone

A235HW
A115HW
A112HW MEGAPHONE
ASSY. D315RP D235MB
A445HW
D236MB
A428HW A428HW
A210HW
A428HW

A128BEC WELDED BAFFLE CORE

ASSY. A127R
A444HW

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 D236IN Rev. 1.0