KAWASAKI VULCAN 800 CRUZER EXHAUST SYSTEM
Part # 31365 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! Important: Read the installation instructions carefully before you begin removing any parts from your motorcycle and if you have any questions, feel free to call our technical help line (562) 926-5291. REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header flange nuts from the front and rear head pipes. 2. Remove the acorn nut located under the rear muffler. 3. Remove the two allen bolts located under the front muffler. 4. Remove the stock exhaust system from the motorcycle and set it aside. 5. Remove the two hex head bolts that attach the stock muffler mounting bracket to the frame of the motorcycle. Remove the muffler bracket and set it aside. 6. Remove the two rubber grommets and spacers from the stock muffler and the one grommet and spacer from the muffler mounting bracket. Set them aside with the the two mounting bolts, they will be reused during installation. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Install the heat shield to the front head pipe using the three 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 front head pipe into the heat shield, 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. 3. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 4. Be sure the steel spacers are in place in the center of the grommets. Install the two allen bolts (from removal step #3) through the mounting bracket and into the frame. Leave them loose at this time. 5. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time. 6. Install the rear head pipe, with the heat shield attached, to the rear cylinder using the stock nuts. Leave them loose at this time. 7. Slide one dog bone shaped nut plate under the bracket that is welded to each muffler. Attach each muffler to the mounting bracket using two 5/16 flanged head bolts (supplied). Leave them loose at this time. 8. Install one hex head bolt (from removal step #5) through the grommet hole on the center of the mounting bracket and into the frame. Leave them loose at this time.

Page 1 of 2

K302IN Rev. 1.1
Align the pipes so theyre parallel when viewing from the right side of the bike, tighten the three mounting bracket bolts on the frame. Tighten the 5/16 flanged head bolts on the back side of both mufflers. 10. Tighten the two nuts on both front and rear head pipes. 11. Rotate the hose clamps on both heat shields so theyre accessible with a screw driver and tighten each of them evenly. Important Note: The end of the heat shield should cover the weld on the muffler body. If not, loosen the heat shield and adjust it fore and aft and re-tighten the hose clamps. 12. 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 a jet kit, call for your application. 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 Mounting Holes Grommet Hole

Figure 1

Front Muffler Mounting Holes

Grommet Holes

VIEW FROM RIGHT HAND SIDE OF MOTORCYCLE

Page 2 of 2

KAWASAKI VULCAN 800 STRAIGHT SHOT EXHAUST SYSTEM
Part # 18383 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! Important: Read the installation instructions carefully before you begin removing any parts from your motorcycle and if you have any questions, feel free to call our technical help line (562) 926-5291. REMOVING THE STOCK EXHAUST SYSTEM 1. Remove the two header flange nuts from the front and rear head pipes. 2. Remove the acorn nut located under the rear muffler. 3. Remove the two allen bolts located under the front muffler. 4. Remove the stock exhaust system from the motorcycle and set it aside. 5. Remove the two hex head bolts that attach the stock muffler mounting bracket to the frame of the motorcycle. Remove the muffler bracket and set it aside. 6. Remove the two rubber grommets and spacers from the stock muffler and the one grommet and spacer from the muffler mounting bracket. Set them aside with the the two mounting bolts, they will be reused during installation. INSTALLING YOUR NEW VANCE & HINES EXHAUST SYSTEM 1. Check the stock exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. 2. Install a chrome header flange onto the front and rear head pipes. 3. Install the heat shield to the front head pipe using the two 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 front head pipe into the heat shield, 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. 4. Install the front head pipe with the heat shield attached, to the front cylinder using the stock nuts. Leave them loose at this time. 5. Install the rear head pipe, with the heat shield attached, to the rear cylinder using the stock nuts. Leave them loose at this time. 6. Install the stock rubbber grommets and spacers into the three large holes on the V&H mounting bar (See figure 1). 7. Slide one dog bone shaped nut plate under the bracket that is welded to each muffler. 8. Slide a chrome muffler clamp (supplied) onto the inlet end of each muffler. Install a 5/16 x 1 1/4 bolt with a flat washer on either side of the clamp followed by a lock nut (hardware supplied). Do this to each muffler but leave the clamp loose at this time. 9. Install one muffler to the four hole bracket welded to the V&H mounting bar using the two 5/16 flange bolts (supplied) and leave them loose. (See figure 1) 10. Slip the muffler and mounting bar assembly onto the front head pipe while aligning the grommet holes in the mounting bar with the holes in the frame. Page 1 of 4 K330IN Rev. 2.2

11. Be sure the steel spacers are in place in the center of the grommets. Install the two allen bolts (from removal step #3) through the mounting bar and into the frame. Leave them loose at this time. 12. Install one hex head bolt (from removal step #5) through the grommet hole on the center bracket of the mounting bar and into the frame. Leave them loose at this time. 13. Slip the other muffler onto the rear head pipe and mount it to the bar using the two 5/16 flange bolts (supplied) and leave them loose. 14. Align the mufflers so theyre parallel when viewing from the right side of the bike, tighten the three mounting bar bolts on the frame. Tighten the 5/16 flange bolts on the back side of both mufflers. 15. Adjust the mufflers and/or heat shields so they match flush where the two parts meet each other. Refer to figure 2. 16. Tighten the two nuts on both front and rear head pipes. 17. Tighten the muffler clamp at the slip joint of each muffler. 18. Rotate the hose clamps on both heat shields so theyre accessible with a screw driver and tighten each of them evenly. Important Note: The end of the heat shield should butt flush with the edge of the muffler body. If not, loosen the muffler and adjust it fore and aft until the heat shield is flush with the muffler body. 19. 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 a jet kit, call for your application. 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.

Page 2 of 4

K330IN Rev. 2.2

Rear Muffler Mount Holes

Grommet Hole

Figure 1

Mounting Bar Front Muffler Mount Holes
Grommet Holes Front Of Motorcycle

MUFFLER

BE SURE THAT THE HEAT SHIELD AND THE MUFFLER MATCH FLUSH WITH NO GAP.

HEAT SHIELD

E IN T D
VIEW FROM RIGHT HAND SIDE OF MOTORCYCLE

Page 3 of 4

Page 4 of 4