Dual Full System Exhaust Instructions For Models: RZR XP® 900 (2011-2014)
SIDE MOUNT REMOVAL:
1. Remove (4) Torx head bolts from the Center Rear Plastic. (See Fig 1)
2. Using a long piece of wire, remove the (4) springs holding the Silencer to the Frame, and the Silencer to the Head Pipe. (See Fig 2)
3. Pull back on the Silencer and slide it to the right to remove it from the vehicle. Be careful not to damage gasket.
4. Remove the seats and Engine Access Panel.
5. Remove (6) Allen head bolts from the Head Pipe Flange at the Cylinder Head. Slide the Head Pipe forward and out of the Engine Compartment, being careful not to lose the Gaskets from the Exhaust Ports.
CENTER MOUNT REMOVAL:
1. Remove the Seats, Front engine cover, Front heat shield, and Rear bumper
2. Use a long piece of electrical wire to remove the springs at the Head Pipe-to-Muffler-Joint.
3. Remove the bolts from the head pipe at the cylinder head.
4. Slide the head pipe forward through the passenger compartment to remove it.
5. Use a long piece of electrical wire to remove the springs from the bottom of the muffler.
6. Slide the muffler toward the passenger side to remove it.
SIDE MOUNT INSTALLATION:
1. Inspect the original gasket for wear. Replace if necessary.
2. Install the HMF Head Pipe and the original Allen Head Bolts. DO NOT TIGHTEN. It may be necessary to bend the right side heat shield slightly to clear the head pipe.
3. Remove the (4) Sub-Frame-to-Frame Bolts.
4. For the next few steps, wedge a small piece of 2”x4” wood between the frame and sub frame to aid in keeping the bolt holes lined up. (See Figure #1)
5. Slide the Silencers over the Head Pipes. Some pushing and twisting may be necessary. Use the supplied bolts and fender washers to attach the Rear Silencer Mounting Tabs to the frame. DO NOT TIGHTEN.
6. Using the supplied hardware, including spacers (at the frame only), mount the Front Silencer Hanger Brackets to the outside of the frame, and the Front Silencer Mounting Tabs. DO NOT TIGHTEN. (See Figure #2)
7. Reposition and zip tie the wiring harness (See Figure #3)
8. Reposition and zip tie the following together: (See Figure #4)
1) Fuel vent hose 2) Oil Lines 3) Ground Cable 4) 12V hot cable
9. Starting at the Head Pipe Flange and working toward the rear of the vehicle, tighten all mounting hardware.
10. Using a spring tool or long piece of electrical wire, (recommended) install the (2) supplied short springs between the Head Pipes and Inlets. (See Figure #5)
11. Inspect all areas around the exhaust system for proper alignment and clearance with plastics, hoses, etc. Adjust where necessary.
12. Replace the Engine Access Panel, seats, and 4 torx head bolts at the rear plastic.
Note: HMF will not be held responsible for damages caused by improper installation.
HMF strongly recommends use of the HMF Optimizer or other suitable tuning device to maintain proper air fuel ratios.
Failure to do so may result in damage to your vehicle.
CENTER MOUNT INSTALLATION
1. Inspect the gaskets in the cylinder head for wear or damage and replace if necessary.
2. Install the supplied heat shield onto the coolant hose on the passenger side of the engine. (See Figure #6)
3. Install the collector onto the primary head pipes.
4. Using the original bolts, install the primary head pipes (with collector) onto the cylinder head over the supplied torque cones. Do not tighten the bolts yet.
5. Slide the S bends onto the collector.
6. Remove the nut from the rear transmission mount and position the muffler bracket onto the vehicle so that it mounts to the rear transmission mount. Use the supplied shoulder bolts, fender washers and nyloc nuts to mount the muffler bracket to the frame. Be sure to install a fender washer on each side of the rubber grommets.
7. Install the nut at the rear transmission mount and tighten the nuts and bolts on top of the muffler bracket.
8. Install the bottom muffler to the bracket first.
9. Install the top muffler to the bracket.
10. Install the 6 supplied springs at the following locations.
11. Install the rear bumper and check all areas around exhaust system for clearance and alignment. Adjust as necessary. Tighten all hardware including head pipe bolts at cylinder head and Oxygen sensor or Oxygen sensor plug. Install the front heat shield, front engine cover, and seats.
NOTE: Check all mounting hardware after initial ride once engine and exhaust has cooled.
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