Dual Full System Exhaust Instructions

Removal

!!! 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 and is not covered under warranty.

1. Remove the (4) bolts holding the rear heatshield and remove the heatshield.  Save these bolts, they will be used later during installation.(See Figure #1)

2. Disconnect the oxygen sensor from the vehicle’s wiring harness.

3. Remove the triangular rubber hangers from both sides of the exhaust hanger brackets.(See Figure #2)

 

Tip: Spray a small amount of lubricant such as a silicone spray between the holes in the rubber hanger and the pins to help them slide off the pins.

 4. Remove the two bolts with springs from the exhaust flange.

5. Remove the (6) allen head bolts from the exhaust hanger brackets and allow the silencer to hang on the exhaust hanger brackets.

6. Support the right side of the silencer and remove the right side exhaust hanger bracket then carefully move the entire silencer to the left and completely remove it from the vehicle.

7. Remove the (2) heat shields above the exhaust.  They are not necessary with the HMF full exhaust.

8. Remove the (4) nuts and washers from the original head pipe.  Save these nuts and washers, they will be used to install the HMF head pipe.

9. Carefully remove the head pipe from the cylinder head and remove the head pipe by rotating it and removing it from the machine.

10. Inspect the sealing gaskets between the head pipe and cylinder head (they may stick inside the cylinder head).  If worn or damaged replace with new OEM gaskets.

Installation

1. Begin securing the provided Honda Talon Full System Bracket with the previously saved heatshield bolts to the rear of the bracket. Do not tighten.(See Figure #3)

2. Secure the front portion of the bracket using the provided (2) 1-1/8” U-Bolts, (4) ¼”-20 Nylcok Nuts, and (4) #10 Flat Washers.(See Figure #4)

3. Carefully install the HMF head pipe and loosely secure it to the cylinder head using the original (4) nuts and washers to the cylinder head.  (See Figure #5)

4. Install the provided HMF mid pipes to the HMF header by sliding them over the head pipe.  The longer of the pipes is installed on the upper head pipe outlet. Ensure the mid pipes are fully seated into the headpipe.  Refer to the image below.(See Figure #6)

5. Install (1) of the silencers with the badge facing outwards using the provided (2) M8-1.25x40 Hex, (2) M8-1.25 Nylock Nuts, (4) 5/16” Fender Washers, and (2) ¼” Flat Washers.  The large 5/16” Fender Washers should be placed on either side of the rubber grommets already installed on the silencer hangers.  

6. While installing the silencers it may be necessary to adjust the rotation of the mid pipes on the head pipe to achieve proper alignment.  (See Figure #7)

(See Figure #8)

7. Install the other silencer in the same manner using the provided (2) M8-1.25x40 Hex, (2) M8-1.25 Nylock Nuts, (4) 5/16” Fender Washers, and (2) ¼” Flat Washers.

8. Check for proper alignment and clearance.  If adjustment is necessary, loosen the hardware holding the silencer to the bracket, adjust, then tighten.  If more adjustment is necessary adjust the bracket on the vehicle’s frame.

9. Tighten all hardware in the following order:

• Silencers to bracket
• Bracket to frame
• Head pipe to cylinder head

10. Install the provided (4) Long Springs between the head pipe and mid pipes and mid pipes to silencers.(See Figure #9)

11. Transfer the oxygen sensor from the original exhaust to the HMF exhaust.  It is recommended to apply a small amount of anti-seize to the threads of the oxygen sensor to prevent the threads from galling.

12. Route the oxygen sensor harness behind the engine and connect the oxygen sensor to the vehicle’s wiring harness.  Pay attention to route the wiring away from any hot or moving components.

13. Wipe off any fingerprints or markings using a 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.

Final Notes:

If you received a stainless steel exhaust without the Blackout coating it is normal for the pipes to change color as they heat cycle.  

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.

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.

Installing Quiet Core Inserts to a dual full system to decrease sound output (particularly in the Performance series) will drastically shorten the interval in which the silencers need to be serviced.  This is due to increased internal silencer pressure and temperature.  Symptoms of a system needing service include: a change in exhaust tone, rattling, loose rivets, etc.  Failure to address exhaust servicing is not covered by HMF's manufacturer warranty.