Installation Instructions for the VMAX (2009-11)

DOCUMENT ID 994341
Brock’s Performance Products • 4064 East Patterson Road • Dayton, OH 45430 • Phone: 937-912-0054 • Fax: 937-912-0062
Installation Instructions for the
VMAX (2009-11) Alien Head and Short Meg Exhaust System
CHECK PACKAGE CONTENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Two (2) Header Mount Flanges (Installed in Head Pipes)
One (1) Left Side Head Pipe (Cylinder 1)
One (1) Right Side Head Pipe (Cylinder 4)
One (1) Left Side Primary Header/Collector
One (1) Right Side Primary Header/Collector
One (1) Secondary Collector
One (1) Mid-pipe
One (1) Gen4 Muffler
One (1) Package Containing Springs, Spring Puller, and
Hardware
10. One (1) Instruction Package
If any parts are missing, contact Brock’s Performance Products.
Brock’s Performance Short Meg System
PRE-ASSEMBLE HEADERS AND COLLECTOR TO ENSURE PROPER FIT BETWEEN ALL PARTS
Brock’s Performance
carefully inspects each
system prior to shipping,
we recommend that you
test fit your system prior
to installation. Apply
WD-40 to the joints to
ease assembly,
adjustment, and/or
disassembly.
REMOVE THE MUFFLERS
Remove the exhaust covers from the front of the mufflers. Loosen the clamp retaining bolt, the bolt only needs to be
loosened not removed. Remove the muffler mounting bolt and slide the muffler rearward to remove, apply a twisting
force to ease removing the muffler. Then proceed to the other side of the bike and repeat.
REMOVE THE CATALYTIC CONVERTER
Remove the EXUP cables from the EXUP servo motor, the motor cannot be removed unless an EXUP servo motor removal
module is purchased to replace it. Disconnect the oxygen sensor from the main wiring harness. The Power Commander 5
comes with an oxygen sensor removal module that will plug into the main harness. Loosen the clamps connecting the
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DOCUMENT ID 994341
front head pipes to the catalytic converter. Remove the clamp mounting bolts from the rear head pipes. Remove the
catalytic convertor mounting brackets from the convertor body and the frame, they are not reused. The left side bracket
br
bolts will need to be replaced as they secure a clip that is to remain on the bike. Slide the catalytic convertor down off of
the rear head pipes, the slide reward to remove.
REMOVE THE HEAD PIPES
Remove the mounting nuts from the flanges of the front cylinders. Loosen the clamp connecting the head pipe crossover
tube together. Remove the head pipes sliding the crossover tube apart. Make sure the gaskets are still in place as they
will be reused for the new system.
INSTALL FLANGES
Remove the flanges from the headers. Using the supplied nuts, attach the flanges with the
larger flared side against the gaskets in the cylinder head and aligned as shown. Make sure
flanges are flat to the gaskets and tighten flanges to 10 ft
ft-lbs to promote a proper seal.
INSTALL REAR HEAD PIPES AND COLLECTOR
COLLECTORS
Assemble the rear head pipes to the secondary
collector and secure with springs. Install the gasket
(donut), collar and clamp loosely to each head
pipe. Slide the assembly up onto the rear
downpipes. Attach the mounting bracket to the
frame with the stock bolts and fasten the tab on
the secondary collector to the bracket with the
provided bolt, washers and nut. Do not tighten
until the full system is installed.
INSTALL HEAD PIPES
Apply a small amount of Permatex Ultra Copper
to inside of the header pipes where they install
onto the flanges. Slide the rear of the pipe
approximately ½” into the rear section until the
front of the pipe can be rotated onto
nto the flange.
Install the head pipes completely onto the
flanges. After one side of the primaries is
installed, attach the springs to the tabs on each
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DOCUMENT ID 994341
end of the head pipe. Then repeat to the other side.
INSTALL MID-PIPE, MUFFLER, AND BRACKET
Slip the mid-pipe over the secondary collector and secure with
one (1) spring. Attach the bracket to the stock mounting
location with the original mounting bolt; the small hole is only
clearance for the stock trim mounting bolt. Slide the muffler
onto the mid-pipe and install one (1) spring. Attach the muffler
mounting tab to the bracket with the supplied bolt, washers,
and nut. It may be necessary to rotate the mid-pipe and
bracket small amounts to get the holes aligned. Check that all
joints are fully engaged and there is clearance around the pipes
then proceed to tighten all the fasteners and downpipe clamps.
CLEAN SYSTEM OF FINGER PRINTS
With any exhaust system you must clean all finger prints off before starting the motorcycle to insure there will not be
finger prints “burned” into the pipe. Carefully use alcohol, brake clean, etc. to clean the system.
ADDITIONAL
Install the Power Commander V and appropriate map for your application.
Brocks Performance Products are designed for Closed-Course Race Track use ONLY.
Brocks Performance Products policies and warranty information: www.BrocksPerformance.com
For additional information: Check our Information Forum at www.BrocksPerformance.com
E-mail [email protected] or call the Order Line 937-912-0054.
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