Baron Exhaust_BIG 'N NASTY PIPES Kawasaki Vulcan 2000 - Manual

Page: 1 BA-1020-03
BIG 'N NASTY MUFFLER SET - KAWASAKI VULCAN 2000
We recommend the use of the factory service manual and the reading of the
instructions fully before beginning the installation to avoid issues or setbacks.
Revision: 2.7 - 04/14/2010
Install Time: Under 1 hour
INCLUDED IN THE KIT:
(2) Big 'N Nasty Mufflers
TOOLS REQUIRED:
Assorted metric wrenches & sockets - 8, 10, 12mm Phillips Screwdriver
INSTRUCTIONS:
The installation of your new Big N Nasty Slip-On Mufflers is reasonably simple. For best results we
recommend you follow the instructions below to save time and effort.
Please read the instructions fully prior to installing the mufflers (It really does save time and effort). If you feel
you don't understand it, please call our technical support line or we suggest you have the product installed by a
competent technician.
DO NOT START THIS INSTALLATION WHILE THE ENGINE OR EXHAUST ARE HOT!
1. Unlock Right Side Cover and remove it from the bike.
2. Remove clamp bolt on the upper heat shield (heat shield not the exhaust mount), just behind and below the
rear passenger peg.
3. Loosen the heat shield clamps on upper muffler starting near the rear cylinder head. You have two mufflers
on this bike; an upper (rear cylinder) and a lower (front cylinder). It is NOT necessary to loosen the shield on
the upper pipe of the front cylinder.
4. Slide the top clamp up and the bottom one forward and detach the clamps from the shields then remove the
upper shield from the pipe.
5. Loosen muffler clamp that connects the muffler section from the head pipe using a 10mm wrench or socket if
you have access.
6. Remove upper muffler bracket bolts that face upwards behind the upper tube below the upper arm of the
swing arm behind the foot peg. Do not lose the metal inserts and rubber grommets that are attached above and
below the mount bracket, these must be reinstalled on the new mufflers).
7. Slide upper muffler off and back from the head pipe being careful to not damage the muffler joint gasket.
(CAUTION: Be careful in the removal of these fabric gaskets, they are necessary for a proper seal with the new
mufflers).
8. Repeat steps 2 thru 7 for lower muffler (NOTE: Only the lower portion of the heat shield needs to be
removed).
9. Slip muffler gaskets back onto the pipes these muffler gaskets have a chamfered edge and a flat sided edge,
Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or
fitment may be required. Barons bears no responsibility on installation costs associated with this product.
© 2013 Barons Custom Accessories
5221 Oceanus Drive Huntington Beach, CA 92649 (925)583-2499 - Ph. (714)901-0520 - Fax www.baronscustom.com [email protected]