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Exhaust Systems Polaris® RZR XP® 1000

HMF Racing Dual Full System Exhaust Instructions

For Models: RZR XP® 1000 (2014-2019), RZR XP® 4 1000 (2014-2019)

Removal

1. Remove the silencer cover.(See Figure #1)

Dual Full System Exhaust Instructions - Figure 1

2. Unplug the Oxygen sensor from the vehicle wiring harness.

3. Remove Silencer-to-Frame springs.  

4. Remove (2) Bolts and Springs at the Head Pipe-to-Silencer Joint

5. Remove the Silencer.  
Note: 2014 Models:
  Use a long piece of electrical wire to remove the Head Pipe-to-Silencer Springs and Silencer-to-frame springs.(See Figure #2)

Dual Full System Exhaust Instructions - Figure 2

6. Remove the Silencer Cover Brackets and Aluminum Heat Shield.

7. Slide the Top Rubber Mounts out of the frame. 

8. Remove the (6) Head Pipe-to-Cylinder Head Bolts and remove the Head Pipe.  The stock bolts can be difficult to remove.  We recommend using a 6mm Long Ball End Socket.

9. Oil Dipstick needs to be repositioned to allow for added clearance from the Head Pipe and easier access from the banner between the seats.

10. Remove the Dipstick by removing the (2) bolts that attach the Dipstick Tube Hold Down to the engine. (See Figure #3)

Dual Full System Exhaust Instructions - Figure 3

11. Push the Coolant Hose out of the way and remove the dipstick tube.  Note: Do Not Remove any Hoses

12. There are (2) Locating Tabs on the Dipstick Tube Flange and (2) on the engine side.  Install the Dipstick Tube 180 degrees from its original position, making the tabs fit into the notches.  It will rest slightly on the inboard coolant hose.  (See Figure #4)

Dual Full System Exhaust Instructions - Figure 4

13. Put the Original Dipstick Tube Hold Down Bolts back in along with the Dipstick.  (See Figure #5)

Dual Full System Exhaust Instructions - Figure 5

Installation

1. Install the Silencer Mounting Bracket to the Chassis using (2) of the Original Mounting Bolts from the Heat Shield for the top of the Bracket.  

2 The center hole on the bottom of the Bracket will fit over the Transmission Mount Stud.

3. Install the (1) Original Transmission Mount Nut onto the stud over the supplied bracket.(See Figure #6)

Dual Full System Exhaust Instructions - Figure 6

4. Hang the Heat Shield by sliding the Heat Shield over the (2) Top Studs on Bracket. 

5. Typically, the OEM Cylinder head-to-head pipe gasket can be reused.  If it is damaged or worn, use the new gasket from your parts kit.  Install the HMF head pipe using the original bolts.  Do not tighten the bolts yet.  (Note:  Insert head pipe between fender and front of shock)(See Figure #7)

Dual Full System Exhaust Instructions - Figure 7

6. Thoroughly clean the right side of the intake manifold, then peel the plastic off of the included Self Adhesive heat shield square.  Install it on the side of the intake manifold.(See Figure #8)

Dual Full System Exhaust Instructions - Figure 8

7. Install the Lower Mid Pipe into the Silencer, then install the assembly to the Head Pipe and Lower Bracket using the supplied M8 Carriage Boltsnyloc nuts, and washers (Install Carriage bolts from the Engine-Side of the Bracket)  Level and center the Silencer and tighten the mounting nuts. 

Dual Full System Exhaust Instructions - Figure 9

8. Install the top mid pipe into the silencer, then install the assembly to the head pipe and top bracket using the supplied nyloc nuts.  Align and center the top silencer and tighten mounting nuts.  Using a long piece of wire, install the supplied head pipe-to-mid pipe springs and mid pipe-to-silencer springs.  

9. Torque head pipe bolts to OEM specs.(See Figure #9)

Dual Full System Exhaust Instructions - Figure 10

QUIET CORES & SPARK ARRESTORS
We do not recommend leaving installed for Extended High Rpm Use such as desert racing.  Leaving the quiet core spark arrestor combo installed in these types of scenarios can result in excessive heat that can cause damage NOT covered under HMF’s warranty policy.

OXYGEN SENSORS

  • 2014 Model Years: No oxygen sensor is used with this machine.  
  • 2015-17 Model Years: Use the provided 18-12mm thread adapter to install the factory oxygen sensor into the HMF exhaust.
  • 2018+ Model Years: Install the factory oxygen sensor directly into the HMF exhaust.  

Discussion

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