How do I remove the stock exhaust system on my Harley-Davidson Touring Model? (VANCE HINES 2016 Harley-Davidson Touring Models Pro Instruction Manual)

Answer

manuals.plus

Jan 26, 2025 - 09:24 PM

To remove the stock exhaust system on your Harley-Davidson Touring Model, please follow the steps outlined in the instruction manual:

1. Remove both left and right saddlebags and set them aside.
2. Remove the right side panel to gain access to the O2 connections.
3. Loosen the bolt from the pinch clamp on the front end of each muffler.
4. Remove the two 5/16” bolts that mount the muffler to the saddlebag supports. Repeat this step on the opposite muffler.
5. Remove the stock mufflers with sliding hangers and set them aside.
6. Unplug the O2 sensor wires (Grey and Black connectors under the right side panel) from the wiring harness and remove cable ties holding front wire to frame. Feed the end of the wires through the frame so they are free from the motorcycle.
7. Remove the right-hand floorboard.
8. Remove the right passenger floorboard or foot peg if so equipped.
9. Loosen the heat shield clamps on both the front and rear exhaust pipes.
10. Remove the nut and carriage bolt holding the front head pipe to the bracket on the transmission housing.
11. Remove the two flange mounting nuts from each head pipe, located at the cylinder head.
12. Carefully remove the head pipes and set them aside.
13. Using a 14mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system.
14. Carefully remove the exhaust port flanges and circlips from the stock exhaust system using snap ring pliers. If the circlips look bent or twisted, replace them.
15. Remove the stock bracket on the transmission housing and install the new bracket (stamped 591-P) (supplied) and torque bolts to 13-16 ft-lbs.
16. Inspect the exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them.

Please note that these are general instructions, and it is recommended to refer to the specific instructions provided in the Vance & Hines instruction manual for your particular model and year of Harley-Davidson Touring Model.