Workshop: UTV Exhaust Install

Cassandra

• May 12 2009
• 289 views
• 8 comments

Before you begin installing a new exhaust system, remember that anytime an aftermarket exhaust system is installed on a carbureted vehicle, you will need to re-jet to compensate for increased flow. The exhaust manufacturer should be able to supply or recommend approximate jetting specs for your altitude.

Step 1

Before getting started, be sure to clean the vehicle thoroughly. Remove both seats and the upper engine covers. Remove all the push rivet-style clips from the center cover and the covers under the seats. Remove the center cover followed by the covers below the seats. With the plastic covers removed, unbolt and remove the metal lower seat plate.

Step 2

Unplug the electrical wiring from the taillights in the cargo bed. Unclip the wiring harness from the bottom of the bed. Unbolt both bed lockdowns and remove the clips and pins that secure the rear of the bed to the frame. Then remove the bed and the Phillips screws from the heat shield under the bed. Remove the shield.

Step 3

With the UTV raised safely on jack stands, crawl under the vehicle and remove the center skid plate. This will require a 10mm socket/ratchet to remove the many bolts. Remove the stock front head pipes from the vehicle first, then you can remove the rear header and muffler assembly.

Step 4

Use a small dab of grease to hold the new exhaust gaskets in place on the cylinder head. You will be leaving all hardware slightly loose until installation is complete. Bolt the No. 1 front head pipe to the front exhaust port using the stock nuts. Bolt the No. 1 rear head pipe to the rear exhaust port. Be sure that the new exhaust gaskets stay in place and centered.

Step 5

Connect the No. 2 front head pipe to the No. 1 front head pipe, securing it with an exhaust spring. Connect the No. 2 rear head pipe/collector to the No. 1 rear head pipe with exhaust spring on the bottom slip joint. Align and fit the No. 2 front header onto the No. 2 rear head pipe/collector securing with the spring. Connect both midsections to the header.

Step 6

Secure the pipe with pipe springs. All muffler bracket bolts will need the supplied, non-permanent Loctite. Be sure to align and properly fit the entire exhaust with sufficient clearances, then remove bolts one at a time for thread lock application. Bolt the top front muffler bracket to the L-bracket, then bolt the L-bracket to the frame-mounting hole.

Step 7

Mount the rear top bracket to the rear cross member by bolting the rear muffler clamps and spacers to the top rear bracket, sandwiching the frame cross tube. Leave it loosely centered on the cross tube. Install the mufflers with the nameplates facing outward. Ensure that the mufflers are pushed completely onto the midsections. Check clearances and then install the lower clamps.

Step 8

Make sure the mufflers are even, then check all clearances. Tighten the head pipe flange nuts followed by the muffler pinch bolts. Check clearances again, then Loctite all the hardware. Install the head pipe heat shield onto the No. 2 front head pipe. Install the top heat shield plate using stock hardware. Reinstall all parts removed for stock exhaust removal.