Mini-Grenades Installation Guide

How to install Vance & Hines Mini-Grenades on a Harley-Davidson Sportster
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Parts List
(1) Front Head Pipe
(1) Rear Head Pipe
(1) Front Heat Shield
(1) Rear Heat Shield
(1) Lower Muffler Can
(1) Upper Muffler Can
(1) Mounting Bracket
(2) Barrel Band Clamp
(6) Hose Clamp
(2) 18mm Copper Washer
(2) 18mm Plug-Zinc
(2) 18-12mm O2 Adaptor
(4) 1/4-20 x 1/2 Flange Bolts
(1) Nylon Cable Tie
Tools Required
- Flat Head Screwdriver
- Combination Wrench: 3/8”, 1/2”, 9/16”, 14mm, 19mm, 22mm
- 3/8” Drive Ratchet w/ 4” extension 1/2”, 9/16” Deep Socket, 7/16” Deep Socket, 3/8”, 10mm, 19mm Socket
- 5/16 Nut Driver
- Allen Wrenches: 3/16”, 5/16”, 10mm Torx: T30
- Snap Ring Pliers
Stock Exhaust System Removal
1. If equipped, 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. Pay attention to the wire routing for re-installation.
2. Loosen the heat shield clamps on both the front and rear head pipes. This allows for easier access to the head pipe mounting nuts.
3. Remove the two head pipe mounting nuts from each flange, located at the cylinder head.
4. Remove the clamp bolts which mounts the rear head pipe to the belt drive cover bracket.
5. Remove the two bolts from each muffler body where they attach to the mounting bar.
Carefully remove exhaust pipes from the motorcycle and set aside.
6. Remove the belt drive cover and take the bracket off the rear cover bolt, this bracket will not be reused.
7. Remove the e-clip from the brake rod lynch pin. Remove the right side rider foot controls.
8. Remove the three mounting bolts and washers attaching the exhaust mounting bar and save the hardware for reuse.
9. Carefully remove the O2 sensors from the stock head pipes and save them for reuse with the new system.
10. Carefully remove exhaust port flanges and circlips from the stock exhaust system using snapring pliers. Replace bent or damaged circlips.
11. Check exhaust port gasket condition and replace if necessary. Harley-Davidson part number: 65324-83B.
Vance & Hines Mini-Grenades Installation Guide
1. Install the supplied mounting bracket, 1123-P, using the stock washers and bolts. Hand tighten only at this time.
2. Using a leveling tool, level the mounting bracket, 1123-P, to ensure that it is parallel with the frame.
3. Torque the mounting bracket bolts to 30-33 Ft./Lbs.
4. Reinstall the drive belt cover. Torque the 3/8” bolt to 30-33 FT./Lbs. and the 1/4” bolts to 80-120 In./Lbs.
5. 2014 - later models re-install brake rod, brake rod lynchpin and e-clip. Re-install foot controls. 2007 - 2013 models, re-install at brake rod eyelet using removable thread locking compound (Loctite ® 243 recommended). Torque to 120-180 In/Lbs. Re-install foot controls with A171HW-P spacer.
6. Remove head pipes and heat shields from their protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a pencil, lightly mark outside edge of each heat shield to show location of mounting clips where hose clamps will loop through. NOTE: Pencil marks can be erased if care is taken not to harm coating.
7. Lay the head pipes into heat shields and loosely install hose clamps by feeding tail end of the hose clamps into heat shield clips. Take note of screw head direction.
8. Apply a small amount of anti-seize compound to the threads of the O2 sensors and install them into the new head pipe. NOTE: 2007 - 2013 models or models using 18mm wideband oxygen sensors install sensor directly into head pipe. 2014 - later models install supplied 18mm to 12mm oxygen sensor adapter then install 12mm oxygen sensors.
9. Install the exhaust port flanges and circlip from the stock system onto the new head pipes.
10. Using stock flange nuts, carefully install the head pipes into exhaust ports. Do not tighten the nuts at this time.
11. Slide the band clamps onto each muffler. Make sure that the nut on the clamps are accessible when installed on the bike.
12. Install and slide the mufflers on one at this time. The muffler with the Vance & Hines logo must be installed on the upper rear head pipe. Hand tighten the muffler bodies to the bracket using the four 1/4-20 x 1/2 flange head bolts.
13. Tighten the band clamps from the mufflers to the headpipes.
14. Make sure to align the head pipes and mufflers then tighten the cylinder port exhaust flange nuts on front and rear cylinders.
15. Tighten the muffler mounting bolts.
16. Reconnect O2 sensors to the wire harness.
17. Be sure to tighten all hardware before staring the motorcycle.