Can Am Outlander 500/650/800/ Full System Titan Series 06-12 Installation Instructions

Removal

1. Remove the following items.

• Seat and Under-Seat Heat Shield.

• Upper-Plastic Air Box Cover under the handlebar area.

• Left and Right-Side Plastic Body Panels and Upper-Plastic Splash Shield under the Right Front Fender. (depending on model) 

• Springs or Clamp (depending on model) from the Silencer Inlet at the Head Pipe Joint.

• Silencer Bolts (clamp mount only) and pull back to remove the Silencer.

• Head Pipe Heat Shield (heat shield will not be reused) and Clamp/Springs (depending on model) holding the two head pipe sections together.  

• Spring Mount Models: Rear Exhaust Hanger.

• Head Pipe-to Cylinder Head Nuts and Head Pipe.  Some pulling and twisting may be required to separate the Head Pipe Sections.  Set the original nuts aside as they will be reused.  Inspect the gaskets for wear and replace if necessary.

2. If your model is equipped with a frame tab, bend the Frame Tab over on the Left-Rear Frame Section. (See Figure #1)

Installation

1. Be sure that the rear Head Pipe-to-Cylinder Head Gasket is installed.  Install the Rear Head Pipe Section and nuts hand tight.

2. Be sure that the front Head Pipe-to-Cylinder Head Gasket is installed.   Install the front Head Pipe Section into the rear Head Pipe Section while aligning the Head Pipe Collar with the Exhaust Port.  Some pushing and twisting may be necessary as this is a snug fit.  Install nuts hand tight.

3. Slide the supplied Clamp over the Silencer Inlet, then slide the Silencer onto the Head Pipe.

4. Using the supplied hardware, fasten the HMF Silencer to the Sub-Frame.  Do not tighten.

5. Inspect all areas of the exhaust system to ensure proper alignment.  Once proper alignment has been achieved, tighten the Silencer Bolts, Head Pipe Nuts, install the supplied Head Pipe Spring, and finally tighten the Clamp.  

6. Temporarily install the left Side Body Panel.  Mark the area where the Head Pipe is closest to the panel.  Remove the panel and apply the included Heat Shield to the inside of the panel at the marked area.  (See Figure #2)

7. Reinstall all the body panels and fasteners as necessary.  

8. Re-inspect all the areas around the exhaust system for clearance with hoses, cables etc.