YAMAHA VIRAGO 700/into 2 EXHAUST SYSTEM
Part # 19561 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 fit. Please read the instructions thoroughly, and compare the parts list with the contents of the box before removing any parts from the motorcycle. REMOVING THE STOCK EXHAUST SYSTEM 1. Loosen the slip joint clamp on the front and rear head pipe, which are located at the muffler box. 2. Remove the two nuts that hold the front head pipe to the engine. Slip the head pipe out of the muffler box and set it aside. Note: Do not remove the rear head pipe, it has been incorporated in the design of the new exhaust system. 3. Remove the muffler box mounting bolt located in front of the passenger foot rest on the left side. 4. Remove two bolts from the right passenger foot rest assembly and set the foot rest aside. 5. Slide the muffler box off of the rear head pipe and set it aside. 6. Replace the muffler box mounting bolt (from step #3) using the washer and nut (supplied) on the back side. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Attach the mounting bar to the motorcycle frame behind the right passenger foot rest. Align the two holes in the largest bracket on the mounting bar with the two holes on the frame, be sure the bend in the mounting bar is pointing to the center of the motorcycle. 2. Install the round steel spacer (supplied) to the rear most hole in the bracket. 3. Attach the foot rest using the two 8mm x 1.25 x 25mm bolts (supplied). 4. Slide the new exhaust flange (supplied) onto the front head pipe. 5. Install the two heat shields to the front head pipe using the four hose clamps (supplied). 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. Place the heat shields onto the front head pipe. Note: Be sure the bend in the heat shield matches the bend in the head pipe exactly. Wrap the hose clamp around the head pipe and give the screw three to four turns, leaving heat shield loose on the head pipe. Repeat this step with the heat shield on the rear head pipe. Note: The screw end of the hose clamp should be accessible, but not visible when pipe is mounted on the bike. 6. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 7. Slide a chrome pinch clamp (supplied) onto the expanded end of the new rear head pipe. Install a 3/8 x 1 bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Repeat this step on the inlet end of each muffler using the two muffler clamps with 5/16 x 1 1/4 bolts (hardware supplied) but leave the clamp loose at this time. 8. Slip the new rear head pipe with the heat shield attached, over the stock rear pipe and gasket, but leave the clamp loose at this time. 9. Install the front head pipe, with the heat shield attached and stock gasket in place, to the front cylinder using the stock nuts, leave them loose at this time. Page 1 of 2 Y305IN Rev. 4.2
10. Slide one dog bone shaped nut plate under the bracket that is welded to each muffler. Note: To define the difference between the front and rear mufflers, view each of them from the outlet end. If the bracket on the backside of the muffler is between the two endcap bolts, you are viewing the rear muffler. If the bracket is inline with one of the endcap bolts, you are viewing the front muffler. Refer to figure #1. 11. Slip the rear muffler onto the rear head pipe. 12. Install the rear muffler to the lower bracket on the mounting bar, using two 5/16x 3/4 flange head bolts (supplied), but leave them loose at this time. 13. Slip the front muffler onto the front head pipe. 14. Install the front muffler to the upper bracket on the mounting bar, using two 5/16x 3/4 flange head bolts (supplied), but leave them loose at this time. 15. Align the mufflers so they are parallel when viewing from the right side of the bike. Tighten the 5/16 flange bolts on the back side of both mufflers. 16. Tighten the two nuts on the front head pipes and the pinch clamp at the rear head pipe slip joint. 17. Tighten the two muffler clamps and the two 8mm bolts where the mounting bar attaches to the frame. 18. Rotate the hose clamps on both heat shields so theyre accessible with a screw driver and tighten each of them evenly. 19. Check the gap between the heat shield and the muffler, it should be about a 1/16, if not, adjust the heat shield and/or muffler to gain the proper clearance. 20. 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 jet kits for most applications. 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 be improved and in some cases may be reduced. Be sure to follow proper installation instructions.

WARNING! VANCE & HINES DOES NOT WARRANTY ANY CHROME PRODUCTS AGAINST DISCOLORATION.
Rear Muffler Rear view of motorcycle

Endcap Bolts

Figure #1

Front Muffler

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Y305IN Rev. 4.2