D480IN

Sportster Straightshots HS
Slip-on Exhaust system

Part #16819
E IN T
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Congratulations, you have purchased the finest exhaust system available for your motorcycle.
Your VANCE & HINES exhaust system is designed and crafted for maximum performance, a perfect fit,
a great sound and unbeatable style! Please follow the installation instructions below and if you have
any questions, feel free to call our technical help line (562) 926-5291.
Attention Installer: (if other than owner): Please forward this instruction sheet to the purchaser of this
product. These instructions contain valuable information necessary to the end user.
STOCK EXHAUST SYSTEM REMOVAL Tools required for installation:

1. Loosen the heat shield clamps on both the front and 1/2” combination wrench
rear exhaust pipes. This allows easier access to the 3/8” drive ratchet and 9” extension
head pipe mounting nuts. 9/16” and 1/2” sockets
2. Loosen, but do not remove, the two head pipe 5/16” Nutdriver/flat blade screwdriver
mounting nuts from each flange located at the
cylinder head.
3. Remove the clamp bolt which mounts the rear head pipe to the belt drive cover bracket.
4. Loosen the clamp holding the mufflers onto the head pipes.
Page 1 of 4 D480IN Rev. 1.1

5. Remove the two bolts from each muffler which attach the Note direction
mufflers to the mounting bar. of bracket
6. Remove the mufflers by sliding them off the head pipes.
7. Remove the clamp from the nose of each muffler (these
will be re-used when installing the new mufflers).
8. Remove the gaskets from the crossover ports on the stock
mufflers. Inspect the gaskets and replace if damaged or
worn (H-D part #65927-00). Install nutplates and
9. Install crossover gaskets onto mounting bar on Figure 1 brackets onto mufflers
motorcycle.
VANCE & HINES EXHAUST SYSTEM INSTALLATION

1. Remove mufflers and heat shields from protective
packaging.
2. Slide the nut plate inside the bracket that is welded to the
backside of each muffler body and attach the muffler
bodies to the mounting brackets (stamped 379-P) using
four 5/16” x 5/8” flange head bolts (supplied). Leave
them loose at this time (Figure 1). Figure 2 Align port with gasket
3. Slide stock exhaust clamp onto nose of each muffler.
4. Slide mufflers onto head pipes and align crossover port
with gasket on mounting bar (Figure 2). Press into place
on gasket.
5. Attach the muffler brackets to the stock mounting bar
using four 5/16” x 3/4” hex head bolts, washers, and
nuts (supplied). Leave them loose at this time (Figure 3).
6. Tighten cylinder port exhaust flange nuts on front and
rear cylinders.
Attach muffler brackets
7. Install and tighten the clamp bolt which mounts the rear Figure 3 to mounting bar
head pipe to the belt drive cover bracket.
8. Align muffler and bracket so they sit level. Tighten the
muffler mounting bolts and the bracket mounting bolts.
9. Tighten the clamp holding the muffler onto the head
pipe.
10. Align head pipe heat shields and tighten all of the hose
clamps.
11. Slide hose clamps into clips inside muffler heat shields.
Note direction of clamp screw heads (Figure 4).
12. Slide heat shields onto muffler bodies so that muffler arrows indicate
Figure 4 clamp head direction
body is recessed 1” inside heat shield and rotate so that
bottom edge of heat shield sits at the 6 o’clock position
(Figure 5). Tighten hose clamps.
13. Check for adequate clearance between all exhaust system components and motorcycle accessories
prone to heat damage.

14. After installation and before starting motorcycle,
completely clean pipes and mufflers with cleaning solvent
and a clean, soft cloth that will not leave a residue.
Note: Any residue, oil, or fingerprints will stain the
chrome when the metal heats up.
15. Be sure to tighten all hardware before starting
motorcycle.
RE-JETTING INSTRUCTIONS Figure 5 Align heatshield

Re-jetting the carburetors will result in realizing the "full"
potential of this performance exhaust system. Vance & Hines Option
offers jet kits for most applications.
Vance & Hines also offers Quiet baffles for
this system, part number 21869. This will
PLEASE NOTE: lower the sound level 2-3db on average.
Every effort is made for Vance & Hines Exhaust Systems to Order it today from your dealer or go to
provide improved cornering clearance. However, due to vanceandhines.com for more information.
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.

PACKING LIST (All parts actual size)
5/16” x 5/8”
Nutplate x 2
Flange head bolt x 4
5/16” x 3/4”
Hex head bolt x 4
5/16” flat washer #28 Hose clamps

x8 x4
5/16” lock nut

x4
HELPFUL HINTS TO AVOID DISCOLORATION OF EXHAUST PIPES

1. Follow owner’s manual instructions regarding use of the choke (starter enricher). If left on longer
than recommended, discoloration may be accelerated.
2. Avoid long periods of idling.
3. Intake leaks can cause engine to run lean and overheat, thus turning the pipes blue.
4. Make sure there are no exhaust leaks at the junction of the exhaust pipe and cylinder head.
5. When installing a new set of chrome pipes, make sure your hands are clean and free of oil. After
installation, thoroughly clean pipes with a cleaning solvent that will leave no residue (glass
cleaner, alcohol, ammonia, etc.) before starting the motorcycle.
WARNING!
VANCE & HINES DOES NOT WARRANTY ANY CHROME
PRODUCTS AGAINST DISCOLORATION.
For information on other Vance & Hines products visit our web site at www.vanceandhines.com

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Sportster Straightshots HS

Slip-on Exhaust system

STOCK EXHAUST SYSTEM REMOVAL Tools required for installation:

Page 1 of 4 D480IN Rev. 1.1

VANCE & HINES EXHAUST SYSTEM INSTALLATION

Page 2 of 4 D480IN Rev. 1.1

RE-JETTING INSTRUCTIONS Figure 5 Align heatshield

Page 3 of 4 D480IN Rev. 1.1

5/16” flat washer #28 Hose clamps

5/16” lock nut

HELPFUL HINTS TO AVOID DISCOLORATION OF EXHAUST PIPES

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