Baron BIG 'N NASTY PIPES Kawasaki Vulcan 2000 User Manual

Page: 1BA-1020-03

BIG 'N NASTY MUFFLER SET - KAWASAKI VULCAN 2000

Revision: 2.7 - 04/14/2010

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.

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 [phone] - Ph. [phone] - Fax www.baronscustom.com [e-mail]

Page: 2BA-1020-03

BIG 'N NASTY MUFFLER SET - KAWASAKI VULCAN 2000

be sure to install with the chamfer edge facing the rear of the bike. Slide the top muffler gasket all the way to
the stop on the head pipe. The lower gasket slides to about 1/4" before the stop. (If you prefer to order new
gaskets the stock part # is 11061-0023).

10. Slip stock muffler clamps onto the Big N Nasty mufflers before installing onto headers. NOTE: The top
muffler clamp should have the bolt head facing up, and the bottom muffler clamp should have the bolt head
facing down.

11. Insert the rubber grommets removed earlier into the large holes on the mount bracket of the lower muffler
and insert the metal sleeves into the front and rear of the grommet.

12. Install the lower muffler onto the lower head pipe first being sure the gaskets stay in/on the clamp-able area
of the head pipe. CAUTION: Do not force the muffler on as you do not want to damage the gasket. You will
know the muffler is on when the mount bracket holes align with the frame mount bracket. Insert the mount
bolts and tighten into place. Now tighten the muffler clamp.

13. Insert the rubber grommets and sleeves removed earlier into the large holes on the mount bracket of the
upper muffler and insert the metal sleeves into the front and rear of the grommet.

14. Install the upper muffler onto the upper head pipe, first being sure the gaskets stay in/on the clamp-able
area of the head pipe. Do not force the muffler on as you do not want to damage the gasket. You will know the
muffler is on when the mount bracket holes align with the frame mount bracket. Insert the mount bolts and
tighten into place. Now tighten the muffler clamp.

15. Re-install heat shields onto headers starting with the upper pipe first. Adjust/align the heat shields with the
new mufflers and then tighten the clamps firmly.

16. Reinstall the side cover.

NOTE: It may be necessary to loosen the head pipes to allow them to be raised or lowered as necessary to
provide parallel alignment of the mufflers. Moving the ends of the head pipes up or down will raise or lower the
front of the mufflers so that alignment can be achieved. We suggest your loosen the muffler clamps in order to
more easily adjust these pipes and to avoid damage to the gaskets.

IMPORTANT: Before starting the bike it is important to check and tighten all hardware and it is wise to clean
the surfaces of the mufflers and head pipe shields to remove all foreign materials, oils, hand and finger prints.
Using a clean cloth and window or chrome cleaner to be sure all surfaces are clean. Failure to clean the pipes
before starting can result in discoloration after the bike is started and the pipes are heated.

Thank you for your purchase, we hope you enjoy the roar of your new Big 'N Nasty Mufflers...We appreciate
your business!

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 [phone] - Ph. [phone] - Fax www.baronscustom.com [e-mail]