Polaris / General / Dual Full System / Performance

Removal

!!! 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. 

1. Remove the (2) bolts at the head pipe-to-silencer joint and the (2) springs that hold the silencer against the frame.  Remove Silencer.  

Note:  You can remove the 2 rubber mounts from the frame as they will not be reused.

2. Remove the top nut from the rear transmission mount.  Save this nut, it will be used later during installation.

3. Disconnect and remove the oxygen sensor from the headpipe.  This will be transferred to the HMF system. 

4. Use a 6MM allen wrench, key or socket to remove the (6) Head Pipe-to-Cylinder-Head bolts and remove the head pipe.  Save the (6) bolts, they will be used to secure your new HMF head pipe.  

Note: It may be necessary to remove the heatshield from above the head pipe to gain access to the bolts.

5. Carefully remove any gasket material left on the cylinder head.

Installation

1. Be sure the cylinder head gasket mating surface is clean from old gasket material.

2. Using the provided RZR 1000 Head Pipe Gasket and original mounting bolts, install the HMF head pipe.  Leave the headpipe loose at this point.  

3. The RZR S 900-1000 / General Exhaust Hanger Bracket fits all variations of the stock Polaris® frames.  See Figure #1 to determine which frame type you have.  If you have a dimple in the frame (Figure #1 A.), proceed to Step 4 and skip step 5.  If you do not have a dimple on the frame (Figure #1 B), proceed to Step 5.(See Figure #1)

4. Install the supplied bracket under the frame rail using the (2) Spacer Brackets (90° bent part), (2) M8-1.25x30 Bolts, (2) 5/16" Fender Washers, (2) 1/4" Flat Washers, (2) M8-1.25 Nylock Nuts along with the original transmission mount nut.
The spacer brackets are inserted from the right side and sit between the vehicle's frame and the top of the bracket to act as a spacer accomodating for the dimple in the frame.  Use the larger fender washers on the top of the frame and smaller washer inside the frame channel.  

5. Install the supplied bracket under the frame rail (Figure #2) using the supplied (2) M8-1.25x30 Bolts, (2) 1/4" Flat washers, (2) 5/16" Fender Washers, and (2) M8-1.25 Nylock Nuts along with the original transmission mount nut.  

Note: Some frames have a hole at Figure #1 B - Arrow #1, and some will have a hole at Figure #1 B - Arrow 2.  Use the mounting hole that is present on your frame to install the HMF Mounting Bracket.

Important: Due to the variation in frames and different tolerances on some machines, there are an additional (2) 3/8" USS Washers (thick washers) that can be used as additional spacers between the frame and mounting bracket.  Before tightening the bracket ensure that it is sitting level within the frame.  Misalignment of the mounting bracket will result in difficulty installing the silencers, clearance issues, and poor alignment.  (See Figure #2)

6. Slide the upper and lower S-bends into the HMF head pipe.(See Figure #3)

7. Install the lower silencer and secure with the provided (2) M8-1.25x20 Hex Bolts, (4) 1/4" Flat Washers, and (2) Nylock Nuts. (See Figure #4)

 

8. Install the upper silencer in the same way the lower silencer was installed and secure with the provided (2) M8-1.25x20 Hex Bolts, (4) 1/4" Flat Washers, and (2) Nylock Nuts. 

9.  Inspect for proper alignment and clearance of all parts, adjust as needed.

10. Tighten the (6) bolts securing the headpipe to the engine.  

11.  Install (2) of the provided Short Springs between the head pipe and the S-bends as well as (2) Short Springs between the S-bends and the silencers.

12. Check that all hardware is secure and the exhaust does not interfere with any moving parts.  

13. Using the 18-12mm O2 Bung Adapter as needed, install the original oxygen sensor to the HMF headpipe.  You may need to slighlty open up the vehicle's wiring loom to route the wiring and connect the sensor.  Ensure the wiring is clear of any moving or hot parts.  

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.