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Exhaust Systems Polaris RZR XP 1000

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HMF Racing Dual Full System Exhaust Instructions

For Models: RZR XP 1000 (2024-2025), RZR XP 4 1000 (2024-2025)

Installation

1. Remove (4) T40 Torx bolts securing Bed Liner in place and remove Bed Liner.

2. Disconnect Rear Tail Light, Brake light and Rear View Camera connections.(See Figure #1)

Dual Full System Exhaust Instructions - Figure 1

3. Remove (14) T40 torx bolts securing Rear Fascia plastics and remove Fascia.

4. At this time loosen and remove 02 Sensor from the Stock Headpipe.(See Figure #2)

Dual Full System Exhaust Instructions - Figure 2

5. Loosen and disconnect V-Band clamp between Muffler assembly and Headpipe.

6. Remove Factory Muffler assembly by disconnecting Retention Springs and sliding the assembly out of the rubber mounts. Note: Remove rubber mount blocks from lower mounts as they are loose and may fall out during riding.(See Figure #3)

Dual Full System Exhaust Instructions - Figure 3

7. Remove the Heat-shield from top of the Factory Headpipe (2) nuts and (1) bolt and set aside for reuse.(See Figure #4)

Dual Full System Exhaust Instructions - Figure 4

8. To ease installation, remove seats, firewall access panels and firewall heat shield.

9. Remove the (6) Allen bolts holding the HeadPipe to the engine and remove the HeadPipe.(See Figure #5)

Dual Full System Exhaust Instructions - Figure 5

10. Install supplied Heat Shield standoff and Worm Clamp onto new HMF Header Pipe loosely.

11. Install new HMF Header Pipe using Factory hardware and new supplied Headpipe Gasket and tighten.

12. Reinstall Factory 02 Sensor in new Headpipe

13. Reinstall both Firewall Heat-shield and upper Header Heat-shield and tighten worm clamp.

14. Using supplied (4) 1-1/8 Aluminum spacers, (4) M6-1.0x 45 hex bolts and (4) #10 Flat Washers remove Factory hardware from the Rear Muffler Assembly Heatshield and install the new HMF Dual Exhaust Bracket .(See Figure #6)

Dual Full System Exhaust Instructions - Figure 6

15. Pre-install lower S-Bend on Lower Muffler (longer brackets) and using provided (2) M8-1.25 Nylock, (2) ¼” Flat washers install Muffler on lower mounting points of Mounting Bracket.

16. Repeat process for Upper Muffler and S-Bend. 

17. Install provided Spring Clamps. (See Figure #7)

Dual Full System Exhaust Instructions - Figure 7

18. Adjust Muffler positions and tighten all hardware. 

19. Reinstall Factory Rear Fascia Plastics and reconnect all Tail Light and Camera connections and reinstall Bed Liner. (See Figure #8)

Dual Full System Exhaust Instructions - Figure 8

Note:  If trimming Rear Fascia Plastics refer to the Rear Fascia Trimming Guide

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Rear Fascia Trimming Guide

While trimming of Rear Fascia Plastics is not required, some customers who wish to have more efficient cooling and better aesthetics may choose to do so.

It is recommended that you use a small reciprocating saw to cut the plastics. However a Oscillating multi tool or dremel tool can also be used.

1. Place tape over the area to be cut and draw a guideline in the crevice along the body line to be cut. (See Figure #9)

Dual Full System Exhaust Instructions - Figure 9

2. Slowly begin cutting just below the line. This will allow room for errors and for corrections to be made later by cleaning up the edge with a sander or razor blade. 

3. Once the cut has been completed you can clean up the edge using some sandpaper wrapped around a stiff backing block like a small scrap of wood to straighten out any uneven cuts.(See Figure #10)

Dual Full System Exhaust Instructions - Figure 10

4. Clean up any remaining burrs left from the cutting and sanding process.(Note:  A razor blade can be held perpendicular to and dragged along the cut edge to clean any small remaining burs.)

Discussion