FMF TheQ User manual

TheQ
TM
S/A Installation
Thank you for purchasing FMF’s QTM muffler for your Polaris Predator 500
. We have spent countless hours
of R & D and testing to insure you receive the highest quality product on the market today.
All FMF's products are developed using the most current design and manufacturing technologies available.
We use only the highest quality materials for function and durability. The QTM
muffler is constructed of an extruded
aluminum canister with a TIG welded stainless steel mandrel bent mid-pipe. Hi-Flo modular endcaps are fitted to
both ends and we utilize advanced 3-stage sound absorption packing material.
The QTM
muffler is specifically engineered to accelerate exhaust flow with less noise and minimal power loss.
Bolt on FMF performance and FEEL THE POWER!
Check out our website at www.fmfracing.com for more information.
Please read all instructions thoroughly before installation
. Failure to follow all installation instructions completely will void any
FMF warranty implied or otherwise. FMF Racing will not be held responsible for problems derived from improper installation and/or improper
usage. Before you begin installing this product, be sure you are wearing eye protection and gloves. You should have a complete
understanding of how to remove and replace your stock exhaust. Otherwise, you should have it installed by a professional mechanic. Keep all
OEM parts when removing your stock exhaust, as some parts may be necessary to install the FMF exhaust depending on your particular
application.
18033 S. Santa Fe Ave.
Rancho Dominguez, CA 90221-5514
PH: 310-631-4363 FX: 310-900-5699
www.fmfracing.com
[04-05 / #000479]
1. Make sure the engine is completely cool prior to installation and the vehicle is in a stable position.
2. Loosen the band clamp connecting the muffler to the header.
3. While holding the muffler, loosen and remove the two OEM muffler mounting bolts. Keep for later use.
4. Gently slide the muffler rearward to release it from the header. Spray WD-40 into the muffler-header
junction if it is difficult to remove.
5. Install the rubber sleeves onto the strap brackets so that the rubber is on the inside of the bracket.
Make sure the outer lip is over the bracket edge fully. No rubber should be in the area where the bracket
tabs pinch together.
6. Using contact cleaner, clean the header where the muffler attaches.
7. Slide the supplied band clamp onto the the muffler inlet. Do not tighten yet.
PARTS SUPPLIED
(2) Medium Strap Bracket
(2) Rubber Bracket Sleeves
(1) 5/16 x 2 1/2” Bracket Bolt
(1) 8mm x 80mm Bracket Bolt
(1) 19mm x 38mm Bracket Spacers
(1) 19mm x 45mm Bracket Spacers
(1) 8mm Flanged Nut
(1) Band Clamp
TOOLS REQUIRED
8mm Wrench
12mm Wrench
Vise Grip Pliers
Contact Cleaner
High Temp Silicone
WD-40®
Spring Puller Tool
REMOVAL
OEM = Original Equipment Manufacturer
PRE-INSTALLATION
2003-2005 POLARIS PREDATOR 500

INSTALLATION
POST-INSTALLATION
8. Lightly coat the slip fit section of the header where the muffler connects with a bead of High Temp Silicone
for an improved seal.
9. With clean hands, gently slide the FMF muffler onto the header. Positioned correctly, the FMF logos
should be at the 3 & 9 o’clock position when looking from the rear. Wipe away any excess silicone.
10. Slide the first strap bracket carefully over the muffler and position it to the front upper mounting point.
Be careful not to scratch the aluminum canister and make sure the “inside” sticker on the bracket is
facing inward to the subframe.
11. To install the mounting bracket, use vise grip pliers to pinch the strap bracket tabs together and install
the supplied 8mm x 80mm bolt and 8mm nut with the 19mm x 38mm aluminum spacer between the
subframe and the bracket. Do not fully tighten at this time.
12. Slide the second strap bracket carefully over the muffler and position it to the rear upper mounting
point. Be careful not to scratch the aluminum canister and make sure the “inside” sticker on the bracket
is facing inward to the subframe.
13. To install the mounting bracket, use vise grip pliers to pinch the strap bracket tabs together and install
the supplied 5/16 x 2 1/2”
bolt with the 19mm x 45mm aluminum spacer between the subframe and the
bracket. Do not fully tighten at this time.
14. Make sure the header and muffler are in neutral positions and not binding. Slowly tighten all mounting
fasteners and clamps to OEM specified torque specs, starting from the front and working your way back.
15.
Inspect the complete exhaust to make sure there is no contact with the frame, shock spring, engine, body
panels or any cables, hoses or wiring. The exhaust system should only be in contact with the exhaust port
and mounting points. Confirm all controls operate in accordance with the manufacturer’s specifications.
16. We recommend using High Temp Silicone for an improved seal. Please follow instructions for the
Silicone and allow sufficient time to dry before starting the engine.
17. Before operating your vehicle, we recommend either stock jetting or installing our Power-Up jetting kit
for optimum performance. Our jetting recommendations are to be used as a guide only and were
developed based on operation at sea-level at 70 degree ambient air temperature. There are too many
variables outside of FMF’s control to give you an exact configuration. If you’re not capable of tuning the
carburetor yourself, please find a mechanic in your area who is capable to take on this role. Refer to our
website for more jetting information.
18. Start the engine and bring it up to operating temperature. Check for exhaust leaks.
19. Let engine cool completely and re-torque all mounting hardware to the manufacturers specifications.
To clean your FMF muffler, allow to cool and use mild soap and water. Do not spray water onto a hot exhaust. Dry completely to prevent
streaking. Mild soap and water works great on the muffler canister to prevent streaking and uneven discoloration.
We recommend repacking your FMF muffler after every 20-30 hours of normal use when properly jetted. This will maintain peak performance
and keep that race tone. Water will ruin the packing. Cover the exhaust outlet when washing your machine. Repack your muffler if water
enters into the chamber. We have various packing materials to choose from. We also recommend cleaning the spark arrestor screen (if
equipped) gently using a wire brush after every 30 hours of use.
To repack the muffler, remove the allen screws from the front of the muffler using a allen wrench. Do not remove the rear endcap. Gently slide
out the front mid pipe from the muffler canister. You may need to use a rubber or plastic mallet to lightly tap it out. Be careful not to damage
the muffler. Unwrap the packing from the core and discard. Wrap the core with new packing and secure with a strip of 1/2” masking tape. Do
not pack too tightly, as this will hamper performance and increase the sound level. Before re-installing the inner core assembly, apply a thin
layer of high temp silicone on the front endcap where the aluminum canister slips over. Slide inner core assembly into canister making sure
the perforated core fully seats in the rear endcap. Wipe off any excess silicone. Re-install the allen screws until snug or tighten 1/4 turn after
the screw makes contact with the canister.
MAINTENANCE
Disclaimer
FMF Racing inspects all products prior to packaging and strives toward improving its products. Our guarantee is limited to the replacement of defective
products. This limited guarantee is in lieu of all other guarantees or warranties implied or expressed. Buyer assumes all risk for any and all damage caused to
himself, a third party and/or property by virtue of failure of this product. We make no warranty as to products distributed by FMF Racing, expressed or implied
from our suppliers or 3rd party vendors. This includes, without limitation, any warranties or merchantability and fitness for a particular purpose. All products are
offered and designed for use with standard machines. FMF Racing makes no claims as to the products effectiveness on modified machines. FMF
Racing is the
sole determiner of abuse, misuse, installation errors and modifications. We assume no liability for any errors in listings, specifications, part numbers, prices or
model applications. We reserve the right to change specifications, product descriptions, product quality, pricing and application at any time without notice and
without further obligation. By installing and/or using an FMF product, you hereby accept and understand these stated terms and conditions and have followed all
instructional steps.