Full System Exhaust Instructions

Removal

1. Remove the large rear plastic fascia and silver heat shielding.  It is optional to re-install these parts at the end.

2. Using a spring puller or piece of wire remove the 4 springs holding the muffler to the head pipe.  These springs will not be reused.

3. Remove the mounting bolts securing the muffler to the frame and remove the muffler.(See Figure #1)

4. Unplug the oxygen sensor from the vehicle's harness.  

5. Remove the original head pipe by removing the (6) 13mm head nuts.  Accessing the head stud nuts will be easier with a long ¼” extension and a swivel. Save all the nuts as they will be used to install the new head pipes. (See Figure #2)

6. Check that the exhaust gaskets for each head pipe are in good condition and in the cylinder head.  If damaged replaced.

Installation

NOTE: Do not tighten any hardware until all parts are installed, this will help with alignment and clearance during the install.

1. Install the (3) long springs between the individual head pipes and the merge collector.  These parts may have shifted in shipping, ensure that all the head pipes are fully inserted to the merge collector. (See Figure #3)

2. Install the assembled head pipe and merge collector assembly.  Some twisting of the head pipes in the merge collector may be needed to align the head pipes to the cylinder head exhaust ports.

3. Align the flanges with the exhaust studs and loosely install the previously removed (6) nuts from the original head pipe.  Do not tighten the nuts.(See Figure #4)

4. Bring in the muffler from the passenger side and slip it onto the end of the merge collector.  Make sure it is fully seated by working it back and forth in a twisting motion.

5. Install the mounting bracket to the muffler using the provided (2) M8 hex bolts, (4) ¼ washers, and (2) M8 nylock nuts.  The bracket will go behind the mounting tabs on the muffler.  Do not tighten. (See Figure #5)

6. Bolt the mounting bracket to the original muffler mounting plate using the provided (2) M10 bolts, (4) 3/8" washers, and (2) M10 nylock nuts.  Do not tighten.

7. Install the (2) long neck springs between the merge collector and muffler.  The long leg of the spring will go towards the merge collector. (See Figure #6)

8. Align the muffler and head pipes as needed.  Tighten the lower mounting brackets first followed by the bolts between the mounting bracket and muffler, and finally the exhaust stud nuts at the cylinder head.   

9. Transfer the original oxygen sensor from the factory head pipe to the new HMF head pipe.  It is recommended to apply a small amount of anti-seize to the threads of the senor when installing.  Do not get any anti-seize on the tip or inside the senor.  Plug the oxygen sensor back into the factory wiring harness.  

NOTE: We have noticed that both with stock exhaust and HMF exhaust the idle on this machine is quite rough until the engine is at full operating temperature.  This is normal and not harmful to the exhaust.