For Models: Maverick X3 (2017-2021), Maverick X3 MAX (2017-2021)
!!! Warning !!! Before working on your machine make sure it is parked on a level surface with the transmission in park and/or the parking brake engaged. Do not work on any machine with a hot engine or exhaust. Allow time for all parts to cool in order to reduce the risk of burns.
Blackout Exhausts: Take care not to get grease or oils on the exhaust. Cleaning our Blackout exhaust with harsh solvents or abrasives will remove the coating.
Tip: Spray a small amount of penetrating oil or similar solvent onto the V-band clamp between the factory downpipe and turbocharger. DO NOT do this while the engine, exhaust, or turbo is hot or fire may occur. This will help the V-band clamp release from the turbocharger and downpipe.
Remove the following:
1. Remove the (2) rear-most torx head bolts from the cargo bed. Install the provided X3 Exhaust Hanger Bracket and secure using the (2) bolts removed from the cargo bed at the top mounting points. Secure the bottom of the hanger bracket using the provided (4) M8x1.25x25 Hex Bolts, (8) ¼” Washers, and (4) M8x1.25 Nylock Nuts. Leave all the hardware loose for now.
2. Transfer the downpipe gasket to the HMF downpipe.
3. Install the HMF downpipe to the turbo using the original V-band clamp. If your clamp is worn or damaged in any way replace it with a new factory one.
4. Do not tighten the V-band clamp at this point. Allow some room for the downpipe to rotate on the turbocharger. This will allow for easier installation of the rest of the system.
5. Position the factory upper and lower heatshields on the HMF downpipe lining up the hole in the upper heatshield for the oxygen sensor. Loosely secure with the original large hose clamps. The hose clamp nearest to the turbo goes through the cutout in the downpipe support bracket. Do not tighten the hose clamps at this point.
6. Prepare the lateral heatshield by removing the hardware from the front bracket and use the provided (3) ¾” Spacers, and (3) M6x1.0x30 Hex Bolts to space the bracket up on the heatshield as shown below. Use the original washers.(See Figure #1)
7. Loosely install the provided Maverick X3 Heatshield Mount Bracket to the lateral heatshield using the provided (1) M6x1.0x20 Allen Bolt, (2) #10 Washers, and (1) M6x1.0 Nylock Nut.(See Figure #2)
8. Slide the lateral heatshield over the HMF downpipe and secure it to the vehicle. Use the original mounting hardware for the forward bracket and the provided (2) M6x1.0x20 Allen Bolts, (4) #10 Washers, and (2) M6x1.0 Nylock Nuts. (See Figure #3)
9. Tighten all hardware securing the lateral heatshield.
Tip: You can protect the HMF downpipe from any minor scratches while installing the lateral heatshield by wrapping the downpipe with a clean rag or other cloth.
10. Install the provided RZR Turbo Gasket on the end of the HMF downpipe.
11. Secure the Flanged Y-pipe to the HMF down pipe using the provided (3) M8x1.25x35 Allen Bolts, (6) ¼” Flat Washers, and (3) M8x1.25 Stonuts. (See Figure #4)
12. Install the lower silencer by sliding it over the Y-pipe and secure it to the hanger bracket using the provided (2) M8x1.25x20 Hex Bolts, (4) ¼” Flat Washers, and (2) M8x1.25 Nylock Nuts.
13. Install the upper silencer by sliding it over the Y-pipe and secure it to the hanger bracket using the provided (2) M8x1.25x20 Hex Bolts, (4) ¼” Flat Washers, and (2) M8x1.25 Nylock Nuts.
14. Check for proper alignment of the silencers. Adjust as necessary. Tighten the hardware securing the silencers to the hanger bracket.
15. Install the provided (2) Long Neck Springs between the Y-pipe and the silencers.(See Figure #5)
16. Double check that the HMF downpipe is fully seated into the turbocharger’s turbine outlet and the V-band clamp is fully engaged around the turbine outlet and HMF downpipe. Tighten the nut on the V-band clamp.
Note: If you used any penetrating oil or solvent to loosen the V-band clamp previously, clean off any remaining oil by wiping it down or spraying it down with a cleaning solvent and allowing it to dry. HMF will not be responsible for any damage or fires due to improper cleaning of combustible materials.
17. Tighten the large hose clamps securing the downpipe heatshields.
18. Tighten all hardware securing the hanger bracket to the machine.
19. Transfer the original oxygen sensor from the factory downpipe to the HMF downpipe. It is recommended to use a small amount of anti-seize on the threads of the sensor to prevent galling when installing it into the downpipe. Do not get anything onto the sensing portion of the oxygen sensor or failure of the senor may occur. Reconnect the oxygen sensor into the vehicle’s wiring harness and route the wiring away from any hot or moving parts.
20. Wipe off any fingerprints or markings using the soft cloth and mild detergent such as soap and water or glass cleaner without ammonia. Once the exhaust heat cycles, any oils left on the exhaust may permanently imprint.
21. Start the engine and check for any leaks. If a major leak is detected, stop the engine immediately and address it. The most common is a leak between the downpipe and turbo caused by an improperly seated V-band clamp.
1. If you received a stainless steel exhaust without the Blackout coating it is normal for the pipes to change color as they heat cycle. Typically with the X3 and the high heat of the turbo the pipes will initially turn a golden color and then progress to a deep blue or purple color with normal use.
2. The HMF Blackout exhaust will smoke and put out an odor for the first full heat cycle as the coating goes through its final curing process, it is recommended to allow this process to happen in a well ventilated area.
3. Near the turbo, the downpipe may begin to glow and show red with extended periods of idling or hard riding, this is normal due to the high exhaust temperatures (particularly visible with the stainless exhaust).
4. All systems will produce a smoke out the end cap after a short initial heat cycle, this is the packing material bedding in and is completely normal.
5. Do not neglect to properly tune this machine when an HMF exhaust is installed.
To install the provided spark arrestors:
1. Remove the (4) end cap bolts and the billet end cap by gently prying it from the shell of the silencer using a screwdriver in the center of the end cap. Take care not to scratch or marr the end cap.
2. Place the spark arrestor with the domed end facing out in the end cap. Reinstall the end cap using the original (4) bolts. Use a small amount of medium strength thread locking compound (typically blue) to the bolts and tighten. It may be necessary to use a soft mallet to seat the end cap back into the silencer. Do not force it.
1. Remove the (4) end cap bolts and the end cap.
2. Place the spark arrestor with the domed end facing out in the end cap. Reinstall the end cap using the original (4) bolts. Use a small amount of medium strength thread locking compound (typically blue) to the bolts and tighten.
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