Suzuki Hayabusa 4:2:1 Competition Series

Part Number 12415

Congratulations, you have purchased the finest exhaust system available for your motorcycle. Your Vance & Hines Motorsports 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 (317) 852-9057.

STOCK EXHAUST SYSTEM REMOVAL (HAYABUSA) #

Please remove the following:

1. Remove and place the lower fairings in a safe place, if necessary refer to service manual. The right-side lower fairing will need to be trimmed for proper exhaust clearance. (Gen I Models – Page 4) (Gen II – Page 5) (22 Model – Lower fairing will require trimming for clearance. Template not supplied; modify bodywork as needed for application)
2. Remove the exhaust fresh air system for this it will be necessary to block off the fresh air- port and plug the air box tube. On Gen II models go to step 3.
3. Remove the oil cooler and mounting bracket. Save the bolts and O-rings for the oil bypass installation.
4. Remove the fan temporarily to aid installation of the exhaust system. On Gen II models go to step 5.
5. Carefully remove complete stock exhaust system from the motorcycle. Disconnect O2 wires on Gen II models.
6. Remove the lower foot peg mounting bolt on the right side. (22 Model) Remove the x2 upper right-side foot peg bolts. Space the foot peg mount out with the x2 supplied washers. The megaphone mount will go behind the lower bolt removed.
7. On Gen II models remove the two lower radiator mounting bolts on the cylinder block, replace with supplied spacers, bolts and washers.

This would be a good time to change the oil and filter. If the O-rings are cracked or stretched, they should be replaced, Suzuki part number # 09280-12012. We also recommend replacing the stock exhaust gaskets, Suzuki part number # 14181-22D01. Note: Stock exhaust gaskets can be replaced with supplied copper gaskets.

COMPETITION SERIES EXHAUST SYSTEM INSTALLATION #

1. Locate the oil bypass kit parts. Wrap the fitting threads with Teflon tape or paste. Thread the fittings to the adapters. The front fitting should be at about (8 o’clock) and the side fitting should be at about (5 or 6 o’clock). Blow air through the oil bypass hose to clean anything that may have been in it. Install the (supplied) O-rings to the adapters and bolt them to the motor using the bolts removed in step 3. Put a drop of oil on the end of the fittings to ease hose installation. Push the hose on until it contacts the plastic ring, there is no need for clamps with this type of hose. 
2. Assemble the header using the pictures (Page 3) as a reference. 
3. Install the exhaust assembly using the stock flange bolts and the foot peg bolt removed in step 6. 
4. After aligning the header, tighten the flange bolts and remove the megaphone and collector so the lower fairing can be installed.

5. A template is supplied to outline the clearance cut that is needed on the right-side lower fairing, we recommend using a Dremel tool or a die grinder. The template should give you the necessary clearance but some fitments may vary. After making the cut lightly sand the edges being careful not to scratch the paint. (Gen I Models – Page 4) (Gen II Models – Page 5)
6. Clean all fingerprints from the exhaust using contact cleaner (or other non-flammable cleaner). Fingerprints will leave stains on the pipe once the motorcycle is started.
7. Try a test fi t. Place a rag or tape over the tail pipes and slowly fi t the lower fairing into place. If you feel more clearance is needed, mark the fairing and remove it. On Gen I models check the clearance at the oil cooler cowl, it will be necessary to trim some material off the cowl. Reinstall the fan if you removed it.
8. Reinstall the megaphone and collector, check that the O2 plug is tight. (22 Model) If using the stock O2 sensors, use the left-side sensor on the right-side and the right-side sensor with the supplied extension on the left-side.
9. You are now ready to start your motorcycle. Check for exhaust leaks and oil leaks. Shut off the bike and recheck the oil level.

For best results, we recommend custom fuel injection mapping for your new combination.