FMF Powerline User manual

PowerlineTM Installation
Thank you for purchasing FMF’s Powerline TM muffler for your Polaris. We have spent countless hours of
R & D and testing to ensure you receive the highest quality product on the market today.
Your Powerline muffler has been developed using the latest design, testing and manufacturing technologies
available. It is manufactured exclusively from stainless steel to provide you with a exhaust that can handle the
heat and abuse that today's utility ATVs bring with them. The PowerlineTM muffler uses strategically placed baffles
and chambers so there is no repacking or re-building necessary.
The PowerlineTM muffler is designed as a maintenance free muffler broadening your existing powerband
giving you an all around power increase without dramatically increasing the sound level.
Check out our website 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.
POLARIS ‘05 RANGER
1. Make sure the engine is completely cool prior to installation and the vehicle is in a stable position.
2. Lift rear cargo section of vehicle to gain access to the muffler. Note: It’s not neccessarry to remove the rear
cargo section but is easier to work on muffler if you do. Refer to the service manual for removal.
3. Using a spring puller tool, remove the two (2) springs connecting the muffler to the mid-pipe (fig.1).
4. Remove the support spring on midpipe (fig.2).
5. While holding the muffler, loosen the two (2) OEM muffler mounting bolts (Fig.3).
6. Gently slide the muffler rearward to release it from the mid-pipe. Spray WD-40 into the muffler/mid-pipe
junction if it is difficult to remove.
7. Using a spring puller tool, remove the two (2) OEM springs that attach the mid-pipe to the header. Keep for later use.
8. Carefully remove the midpipe from the header. Spray WD-40 into the muffler/mid-pipe junction if it is difficult
to remove. Make sure to keep the existing exhaust port gasket. This will be reused if in good condition.
9. Using contact cleaner, clean the section of the header where the mid-pipe fits and lightly coat with a bead of
High Temp Silicone for an improved seal.
REMOVAL
OEM = Original Equipment Manufacturer
PRE-INSTALLATION
18033 S. Santa Fe Ave.
Rancho Dominguez, CA 90221-5514
PH: 310-631-4363
FX: 310-900-5699
www.fmfracing.com
[12-05 / #000694]
PARTS SUPPLIED
(1) Powerline Muffler 045108
(2) Strap Bracket 940334
(2) 6mm Nut & Bolt 920140/ 921025
(2) 8mm x 30mm Bolt 920167
(2) 8mm Nut 920142
(2) Aluminum Spacer 920099
TOOLS REQUIRED
8mm Wrench
10mm Wrench
12mm Wrench
1/2” Wrench
Vise Grip Pliers
Contact Cleaner
High Temp Silicone
WD-40®
Spring Puller Tool
INSTALLATION
10. With clean hands, gently slide the FMF muffler onto the header. Wipe away any excess silicone.
11. Slide the fisrt strap bracket carefully over the muffler and position to the front mounting point. Be careful not
to scratch the canister and make sure the “inside” sticker on the bracket is facing inward toward the center of
the machine.
12. To install the mounting bracket, use vise grip pliers to pinch the strap bracket tabs together and install the
supplied 8mm x 30mm bolt and nut to attach the strap bracket to the frame with the supplied spacer between
the subframe and the strap bracket (Fig.4). Do not tighten and keep loose to properly adjust to mounting points.

INSTALLATION
POST-INSTALLATION
13. Install the supplied 6mm bolt and nut in the lower hole of the strap bracket. Once installed, the 6mm
bolt and nut remain intact to keep the mounting bracket in place. Do not fully tighten at this time.
14. Repeat steps 11-13 for mounting rear strap.
15. Install the two (2) stock OEM exhaust springs from the mid-pipe to the header using a spring puller tool.
16. 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.
17. 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 OEM specifications.
18. 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.
19. Before operating your vehicle, we recommend either stock jetting or installing our Power-Up Jet 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.
20. Start the engine and bring it up to operating temperature. Check for exhaust leaks.
21. Let engine cool completely and re-torque all mounting hardware to OEM specifications.
To clean your FMF muffler, allow to cool. Do not spray water onto a hot exhaust. Dry completely to prevent streaking. Mild soap and water is
recommended on the muffler canister to reduce streaking and uneven discoloration.
The PowerLine muffler is a mechanical design and has no packing material - it will not require any packing maintenance. The PowerLine does
have a screen type spark arrestor and we recommend cleaning the screen gently with a wire brush after every 30 hours of use.
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.
Fig.1
Fig.2
Fig.3
Fig.4
6mm nut faces outwards.