HONDA AERO 750 CRUZER EXHAUST SYSTEM GUIDE

STOCK EXHAUST SYSTEM REMOVAL

Remove frame cover.
Remove right side footpeg assembly held in place by two bolts (Figure 1).
Remove exhaust port nuts.
Remove bolts securing rear muffler to exhaust system mounting bracket.
Remove complete exhaust system. Begin by lifting muffler out of mounting bracket locating hole (assistance may be required).
Check condition of stock exhaust gaskets. Replace if damaged or worn.
Remove two bolts attaching stock exhaust mounting bracket to frame.
VANCE & HINES EXHAUST SYSTEM INSTALLATION

Install mounting bracket (stamped 363-P) in the original muffler mounting position, using two 10mm bolts and 10mm nuts. (supplied)(Refer to figure 2).
Mark outside surface of front and rear heat shields with location of mounting clips that are welded to the inside.(Refer to figure 3).Place each heat shield on a non-abrasive surface such as a blanket or carpet. Position each head pipe/muffler over its respective heat shield. (Refer to figure 4).
Feed tail end of each hose clamp through each mounting clip welded to back side of front and rear heat shields. Take note of clamp hex screw head direction. (Clamp head direction is critical for adjustment when system is installed on bike.) Wrap each clamp around back side of head pipe threading tail end into clamp head. (Refer to figure 3 & 4).
Install front head pipe/muffler using stock flange nuts. Slide dog bone shaped nutplate (supplied) inside bracket welded to backside of muffler. Attach muffler to mounting bracket 363-P using (supplied) 5/16” flange bolts engaging dog bone nutplate. Leave head pipe/muffler assembly loose at this time (Refer to figure 4). Repeat this step with the rear head pipe.
Align mufflers so they are parallel when viewing from right side of the motorcycle. Tighten 5/16” flange bolts securing upper and lower muffler positions.
Tighten cylinder exhaust port flange nuts securing head pipes to cylinder heads.
Adjust heat shields so they meet front of muffler taper. (Refer to figure 6). Tighten all hose clamps securing heat shield locations. NOTE: Heat shields should cover muffler/head pipe weld joint.
Reinstall right side footpeg.
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