Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your Vance & Hines exhaust is designed and crafted for maximum performance, a great sound and unbeatable style. Please follow the instructions below, check exhaust system for missing or damaged parts and if you need any assistance please contact our technical support line (562) 921-7461.

TOOLS REQUIRED

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.

READ ALL INSTRUCTIONS BEFORE BEGINNING INSTALLATION

STOCK EXHAUST REMOVAL

MORE POWER : LESS NOISE

HARLEY-DAVIDSON® 09 XR1200 WIDOW XR 2-1-2 EXHAUST INSTALLATION INSTRUCTIONS PART# 47537

FIGURE 1

1. Find and unplug the O2 sensor wires from the wiring harness. Feed the end of the wires through the frame so they are free from the motorcycle. NOTE: Pay attention to wire routing for re-installation. 2. Remove the clamp bolt from the front head pipe support. NOTE: This bolt will not be used for re-installation. 3. Lossen the two mounting nuts from each head pipe, located at the cylinder head. 4. Remove the muffler assembly by loosening and removing the two bolts that hold the mufflers to the stock hanger mounts. Save the hardware for re-installation. 5. Remove the cylinder head nuts and head pipes, carefully set them aside.

6. Using a 7/8” or 22mm wrench, carefully remove the O2 sensors from the stock head pipes and save for re-use with the new system. 7. Carefully remove the exhaust port flanges and circlips from the stock exhaust system using snapring pliers. NOTE: If circlips look bent or twisted, replace them. 8. Remove the belt cover. 9. Remove the head pipe support bracket. Re-install the belt cover and use the supplied washer 7-70121 as a spacer between the belt cover and the engine case on the lower bolt hole. 10. Inspect the exhaust gaskets to be sure they are in good shape. If you have any doubts as to their condition, replace them. We Recommend Harley Davidson replacement gaskets #17048-98.

FIGURE 2

7-70108 7-70107 Page 1 of 3

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HARLEY-DAVIDSON® 09 XR1200 WIDOW XR 2-1-2 EXHAUST INSTALLATION INSTRUCTIONS PART# 47537

2. Apply a small amount of anti-seize compound to the threads of the O2 sensor and install them into the new head pipes. Note: Be careful not to get anti-seize on sensor tip, it may affect sensor function. 3. Install the flanges and circlips removed earlier.

VANCE & HINES EXHAYST INSTALLATION

MORE POWER : LESS NOISE

1. Locate the front head pipe 7-80329 and rear head pipe 7-80330.

4. Install muffler bracket 7-70105, refer to figure 1, use the stock hardware for the front mount. The rear mount uses the original bolt with the supplied washer 7-70107 and lock nut 7-70108. The washer goes between the hanger mount and the muffler bracket, refer to figure 2. Do not install the lock nut until the mufflers are mounted as it will be in the way of the muffler mounting hardware. 5. Using the stock flange nuts, carefully install the head pipes into ports beginning with the rear cylinder. Note: Do not tighten the flange nuts completely at this time. 6. Locate the cross over collector 7-40047. Install it to the head pipes, attach with the supplied springs 7-30009 using supplied spring tool. 7. Locate the upper muffler/tail pipe assembly. Slide it on the Collector and install it to the muffler bracket with a dog bone nut plate A195HW and loosely install the two 5/16” flange bolts (supplied). 8. Repeat step 7 with the lower muffler/tail pipe assembly. 9. Align both mufflers and tighten the flange nuts. Install the tail pipe springs to the collector and tighten the cylinder head nuts. Install the lock nut to the rear muffler hanger bolt. 10. Check for adequate clearance between all exhaust system components and those motorcycle accessories prone to heat damage. 11. Be sure to check and tighten all hardware before starting your motorcycle.

EXHAUST CARE - HELPFUL HINTS KEEP YOUR EXHAUST LOOKING NEW 1. When installing a new set of black pipes, make sure your hands are clean and free of oil. After installation, thoroughly clean pipes with warm soapy water and a soft cloth. Dry with clean towel to remove any residue before starting the motorcycle. Do NOT use anything abrasive to clean pipes.

2. Avoid long periods of idling as this can cause discoloration. 3. Intake leaks can cause the engine to run lean and overheat, this could lead to discoloration. 4. Make sure there are no exhaust leaks at the junction of the exhaust pipes and cylinder head. We recommend replacing gaskets if they are worn.

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 3

I47537 Rev. 1.0

HARLEY-DAVIDSON® 09 XR1200 WIDOW XR 2-1-2 EXHAUST INSTALLATION INSTRUCTIONS PART# 47537 PACKING LIST

47537: 2009 WIDOW XR 2-1-2 SYSTEM

ALL PARTS SHOWN ARE ACTUAL SIZE

MORE POWER : LESS NOISE

47537 INTERNAL BOM PART NO. 7-50098 7-50099 7-80329 7-80330 7-40047 7-50089 7-50090 7-70105 7-70107 7-70108 7-70121 7-30009 A195HW 7-70046 7-70014 7-60059 7-60007 7-30004

DESCRIPTION Muffler Assy./Baffle Assy., Upper Muffler Assy./Baffle Assy., Lower Front Hd Pipe Assy. Rear Hd Pipe Assy. Collector Assy., MS Tail Pipe/Muffler Assy, Upper Tail Pipe/Muffler Assy, Lower Muffler Bracket Assy. Flat Washer, 5/16" Centerlock Hex Locknut, 5/16"-18 Flat Washer, 1/4"ID, 9 Ga Spring, BC Dog Bone Nut Plate Bolt, Flange Serrated 5/16-18 x 5/8 Bolt, BHCS 1/4"-20 x 5/8" Baffle Assy. Baffle Packing Exhaust Spring Puller Tool

STOCK EXHAUST: 33 lbs 47537: 19 lbs 7-70014

BAFFLE ASSY. 7-60059

QTY 1 1 1 1 1 1 1 1 1 1 1 4 2 4 4 2 2 1

FRONT PIPE ASSY. 7-80329

REAR PIPE ASSY. 7-80330 EXHAUST SPRING PULLER TOOL 7-30004 SPRING 7-30009

MUFFLER/BAFFLE ASSY. 7-50098

TAIL PIPE/MUFFLER ASSY. 7-50089

COLLECTOR ASSY. 7-40047 BAFFLE PACKING 7-60007

7-70046

A195HW 7-70107

MUFFLER/BAFFLE ASSY. 7-50099

TAIL PIPE/MUFFLER ASSY. 7-50090

7-70121

BKT ASSY. 7-70105

7-70108

WARRANTY Vance & Hines products 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 products 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 3

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