HARLEY-DAVIDSON® SPORTSTER

SRAIGHTSHOTS HS
INSTALLATION INSTRUCTIONS
PART# 17821

Congratulations, you have purchased the finest exhaust system for your
motorcycle on the market. Your Vance & Hines exhaust system is designed
and crafted for maximum performance, a perfect fit, a great sound and
MORE POWER : LESS NOISE

unbeatable style. Please follow the installation instructions below and if you
have any questions, please call our technical support line at (562) 926-5291.

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.

Snapring Pliers
Flat Blade Screwdriver

REQUIRED
5/16” Nut Driver ft/lb, in/lb Torque

TOOLS
s.
Ft./
Lb
Wrenches
1/2”, 9/16, 7/8” or
22mm Wrenches 3/8” drive Ratchet

3/16”, 5/16” Allen

1/2”, 9/16” Sockets
Wrenches
3/8” Drive Extensions
T30 Torx Wrench

READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION

NOTE: These instructions are written for late model motorcycles equipped with O2 mounting bar. Carefully remove exhaust pipes from the motorcycle and set
sensors. If you are installing this system on a motorcycle not equipped with O2 aside.
sensors you will need to contact our Customer Service Dept. to purchase an O2 6. Using a 7/8” or 22mm wrench, carefully remove the O2 sensors from the stock
SYSTEM REMOVAL
STOCK EXHAUST

sensor block off kit P/N 16925 head pipes and save for re-use with the new system.
1. Find and unplug the O2 sensor wires from the wiring harness and remove the 7. Remove the drive belt cover and take the bracket off the rear cover bolt, the
reusable clamp or nylon cable tie (whichever is being used) holding front wire bracket will not be re-used.
to frame. Feed the end of the wires through the frame so they are free from the 8. Loosen and remove the brake rod at the rear eyelet using a T30 torx driver.
motorcycle. NOTE: Pay attention to wire routing for re-installation. 9. Remove the three mount bolts and washers attaching the exhaust mounting bar
2. Loosen the heat shield clamps on both the front and rear exhaust pipes. This (save hardware for re-use).
allows easier access to the head pipe mounting nuts. 10. Carefully remove exhaust port flanges and circlips from the stock exhaust system
3. Remove the two head pipe mounting nuts from each flange, located at the using snapring pliers. NOTE: Replace bent or damaged circlips. Check exhaust
cylinder head. port gasket condition. Recommended replacement exhaust port gaskets, Harley
4. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover part number:17048-98 or 65324-83A.
bracket.
5. Remove the two bolts from each muffler body where they attach to the

FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4

Install Bracket 356-P

Hold bracket level with frame Mark edge of pipe
while tightening to locate clip - install tail first
Page 1 of 4 D810IN Rev. 1.0
 FIGURE 3 FIGURE 4 FIGURE 5 FIGURE 6

2. Install Circlip

1. Install Flange

Adjust for even gap

MORE POWER : LESS NOISE

Insert nut plates into

brackets

1. Install and tighten supplied mounting bracket (stamped 356-P) 7. Install circlips and flanges from the stock system onto both new
(Figure 1) using stock washers and bolts. Torque to 30-33 Ft/Lbs. head pipes. (Figure 4)
NOTE: Support the rear of the bracket during tightening to insure 8. Using stock flange nuts, carefully install head pipes into exhaust
it is align with the bottom edge of frame ports (Assistance may be required). NOTE: Do not tighten at this
2. Re-install drive belt cover. Torque the 3/8” bolt to 30-33 time.
VANCE & HINES EXHAUST

Ft/Lbs. and the two 1/4” bolts to 80-120 In/Lbs. 9. Slide nut plates inside brackets welded to backside of muffler
SYSTEM INSTALLATION

3. Re-install brake rod eyelet using removable thread locking bodies (Figure 5). While holding nut plates in place, attach
compound (Loctite® 243 recommended). Torque to 120-180 In/ muffler bodies to mounting bracket 356-P using four 5/16”x 5/8”
Lbs. flange head bolts (supplied). Leave them loose at this time.
4. Remove header pipes and heat shields from protective packaging. 10. Tighten cylinder port exhaust flange nuts on front and rear
Place each heat shield on a non-abrasive surface such as a blanket cylinders while making sure pipes are parallel. (Figure 6)
or carpet. Using a felt tip pen, mark outside edge of each heat 11. Tighten the flange bolts on both mufflers and all heat shield
shield to show location of mounting clips where hose clamps will clamps.
loop through (Figure 2). 12. Plug O2 sensors back into wiring harness and route wires away
5. Lay head pipes into heat shields and loosely install hose clamps from hot areas of motorcycle.
by feeding tail end of clamp into heat shield clips (Figure 2). Take 13. Re-install the reusable clamp or install a new nylon cable tie
note of screw head direction (Figure 3). Screw heads should be (supplied) to hold the front wire onto the frame in the original
accessible when system is installed on motorcycle for adjustment location.
purposes. Use #20 hose clamps on head pipes and #28 hose 14. Check for adequate clearance of all exhaust system components
clamps on muffler bodies (supplied). and motorcycle accessories prone to heat damage.
6. Apply a small amount of anti-seize compound to the threads of 15. Be sure to tighten all hardware before starting
the O2 sensors and install them into the new head pipes. NOTE: motorcycle.
Be careful not to get anti-seize on sensor tip, it may affect sensor
function.
EXHAUST CARE - HELPFUL HINTS TO AVOID DISCOLORATION OF EXHAUST SYSTEM
1. When installing a new set of chrome 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 a soft cloth and cleaning solvent that will leave 3. Intake leaks can cause the engine to run lean and overheat, this could lead to discoloration.
no residue (chrome wax / polish, glass cleaner, alcohol, ammonia, etc...) before starting the 4. Make sure there are no exhaust leaks at the junction of the exhaust pipes and cylinder head.
motorcycle. We recommend replacing gaskets if they are worn.

VANCE & HINES OPTIONAL ACCESSORIES

FUEL MANAGEMENT:
FUELPAK

BAFFLE

Take the guess work out of fuel injection with Fuelpak Fuel Quiet baffle P/N 21869 is available for this
QUIET

Management. Contact your local dealer or call (562) 921-0071 system. The quiet baffle will lower the sound
to order. Visit fuelpakfi.com for more information. level by 2-3db on average. Contact your local
Fuelpak is intended for racing or off-highway use only, and is dealer to order.
not legal for sale or use in California on pollution-controlled
vehicles.

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 4 D810IN Rev. 1.0

 HARLEY-DAVIDSON® SPORTSTER
STRAIGHTSHOTS HS
INSTALLATION INSTRUCTIONS
PART# 17821
PACKING LIST
MORE POWER : LESS NOISE

Nylon Cable Tie x 1

ALL PARTS SHOWN ARE ACTUAL SIZE

#20 Hose Clamps x 5 #28 Hose Clamps x 2

Nut Plate x 2

PARTS NOT SHOWN:

356-P Bracket x1
5/16” x 5/8” Flange Head Bolt x 4 D605FC Front Header Assembly x1
D606FC Rear Header Assembly x1
D605HC Front Muffler Heat Shield x1
D606HC Rear Muffler heat Shield x1

WARRANTY
Vance & Hines exhaust systems 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 exhaust systems 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 4 D810IN Rev. 1.0

 FUEL MANAGEMENT
GET THE MOST OUT OF YOUR RIDING EXPERIENCE...
AN AFTERMARKET EXHAUST SYSTEM IS ONLY YOUR FIRST STEP, NOW YOU NEED FUEL MANAGEMENT.

NOW YOU NEED FUELPAK.

MORE POWER : LESS NOISE

Your fuel injected Harley-Davidson® is equipped with an ECU (electronic

control unit) that’s programmed to deliver fuel to the motor based on an
air/fuel ratio for a stock air filter and stock exhaust system. When you install
a performance exhaust system, your airflow changes, so you need a
fuel management system that adjusts your air/fuel ratio to match
the changes. That fuel management system is Fuelpak. Fuelpak
adds and takes away fuel, allowing for a more precise range of
refinement in your air/fuel ratio. Get the perfect fuel management
combination with your Vance & Hines exhaust system, get Fuelpak.
For more information visit the tuning center at fuelpakfi.com

NOTICE: Fuelpak is intended for racing or off-highway 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
VANCEANDHINES.COM
Page 4 of 4 D810IN Rev. 1.0