The World According to Zuki Dude Page 1 of 10 Zuki Dude’s M50 How To for the Vance & Hines Cruzer Exhaust System Hear the difference (click one): Stock vs. V&H Welcome to my How-To instructional supplement for the Vance & Hines Cruzer exhaust system as installed on the 2005 Suzuki M50. This step-by-step procedure also applies to the Volusia 800 and C50 models. I have made every attempt to cover the full installation with what I feel are helpful pictures and tips. Please note I am not a licensed mechanic; only a serious enthusiast with tons of mechanical experience. As such, you the installer and/or installee assume all risk and liability associated with these instructions, installation, safety and state laws where applicable. In other words, you agree to not hold me liable for damages in any way, shape or form to your bike or person for your own neglect and/or stupidity. Let’s begin. Tools Needed: Clean work space 4.0 Metric Hex Key 6.0 Metric Hex Key Socket Wrench 12mm Socket 12mm Wrench 8mm Socket ½ inch Socket ½ inch Wrench Flathead Screwdriver http://www.zuki-dude.net/vance-and-hines-how-to.htm 5/26/2006 The World According to Zuki Dude Page 2 of 10 Note: Your Vance & Hines Cruzer exhaust system does not come with gaskets. If you are careful during the stock exhaust system removal on a low mile motorcycle, chances are you can reuse the stock gaskets. If you are unsure, please be sure to acquire replacement gaskets from your dealer/retailer. Tip: I completed my install using only hand tools, no power. If you use power tools, please be aware of your torque settings so as not to strip any nuts, bolts or bolt heads. Stock Exhaust System Removal 1. Start by removing the decorative top side panel above the rear exhaust pipe using a 4.0 Metric Hex Key to remove the hex bolt on top. Carefully pull off towards you. Place the cover somewhere out of the way so it doesn’t get damaged. 2. If you are using hand hex wrenches, remove the two hex screws from the top of the air filter box. This will allow more hand and wrench clearance when removing the rearmost hex screw from the exhaust connecting it to the cylinder. If you are using a flexible extension with a power tool, you can proceed to step 3 if you choose. 3. Remove four exhaust port bolts that connect the pipes to the cylinders (two each port) using a 6.0 Metric Hex Key. Place these bolts aside as they will not be reused. Tip: The picture below shows exactly why to loosen the air filter box so as your hand can get behind it in order to turn the bolt. Due to the curvature of the pipe as it exits the cylinder, it is nearly impossible to turn otherwise. http://www.zuki-dude.net/vance-and-hines-how-to.htm 5/26/2006 The World According to Zuki Dude Page 3 of 10 4. Remove the two nuts from the backside of the bolts (first picture below) holding the rear section of the pipes to the frame using the 12mm socket and wrench. Tip: The Vance & Hines (V&H) instructions incorrectly state these as 8mm, unless Suzuki at one time used different sizes or switched during the manufacturing process. Remove the backside nuts (second picture below) and allow the bolts to remain in so as the exhaust pipes do not fall. http://www.zuki-dude.net/vance-and-hines-how-to.htm 5/26/2006 The World According to Zuki Dude http://www.zuki-dude.net/vance-and-hines-how-to.htm Page 4 of 10 5/26/2006 The World According to Zuki Dude Page 5 of 10 5. If you do not have assistance, center yourself to the exhaust by kneeling down and grasping the front and rear sections of the pipes firmly and pull straight off the motorcycle towards you. Be cautious so as not to scratch any painted or chrome sections of your bike. Place your exhaust somewhere out of the way so it doesn’t get damaged. Tip: Sell it on e-Bay! You’re not going to want it anyway, right?! Your motorcycle should now look something like this: http://www.zuki-dude.net/vance-and-hines-how-to.htm 5/26/2006 The World According to Zuki Dude Page 6 of 10 Vance & Hines Exhaust System Installation 1. Check the condition of your OEM exhaust port gaskets. Tip: They may still be inside the circular rim of the exhaust ports on the cylinders. If worn or damaged, replace them before proceeding. 2. Prepare a clean non-abrasive area to lay your new pipes; preferably on a soft towel. Lay the heat shields face down taking precautions not to scratch. Note the welded mounting clips inside each shield; they should be facing you. Place each pipe into the appropriate shield as they will mount on the bike. http://www.zuki-dude.net/vance-and-hines-how-to.htm 5/26/2006 The World According to Zuki Dude Page 7 of 10 3. Install the provided hose clamps by feeding the tail end through one mounting clip and pushing all the way through so as the tail end come back around through the opposite mounting clip. Tip: The V&H instructions state to mark each clip on the outside of the heat shield. I found this unnecessary, as the hose clamp will follow the shield’s radius. Use your own discretion. Refer to V&H instructions Figure 2 picture for proper orientation of the hose clamp heads. Secure each clamp, but do not fully tighten just yet; see above picture. 4. Attach the supplied muffler bracket to the rear of the motorcycle reusing the 12mm nuts and bolts from removal of the OEM exhaust, as shown here: http://www.zuki-dude.net/vance-and-hines-how-to.htm 5/26/2006 The World According to Zuki Dude Page 8 of 10 5. Install the longer front pipe by kneeling down and inserting the exhaust port into the cylinder head. Using one hand to firmly hold the rear of the pipe, loosely install both hex bolts connecting the pipe to the cylinder; just enough to keep in place. 6. While still holding the rear of the pipe, insert the dog bone shaped nut plate (V&H supplied) inside the welded bracket on the back side of the muffler. 7. From the back side of the muffler bracket, install the provided ½” bolts through the bracket and into the dog bone nut plate. Tip: This is a bit tricky as you must hold the muffler and align the dog bone nut plate with the bolt. I did it single handedly, but if you can get assistance it would make it that much easier. Once both nuts are installed, tighten them firmly with the ½” socket/wrench. http://www.zuki-dude.net/vance-and-hines-how-to.htm 5/26/2006 The World According to Zuki Dude Page 9 of 10 8. Repeat steps 5, 6 and 7 for the shorter pipe. 9. Now tighten the exhaust port bolts that connect the front and rear head pipes to the cylinders using the 6.0 Metric Hex Key. Careful not to over tighten. 10. Be sure to align the heat shields such that they cover any weld joints at the muffler end. Tighten all hose clamps using a flat-head screwdriver or 8mm socket. 11. Reinstall the air cleaner box’s bolts. 12. Reinstall the decorative side panel. 13. Shine up that chrome! No fingerprints or oil should be on the pipes or heat shields prior to starting your motorcycle. BE SURE ALL HARDWARE IS PROPERLY TIGHTENED BEFORE STARTING MOTORCYCLE! Enjoy the new sound and performance of your Vance & Hines Cruzer exhaust system! http://www.zuki-dude.net/vance-and-hines-how-to.htm 5/26/2006 The World According to Zuki Dude http://www.zuki-dude.net/vance-and-hines-how-to.htm Page 10 of 10 5/26/2006