Polaris 2016 RZR 4 900 User manual

Slip On Exhaust Instructions
For Models: RZR® 4 900 (2015-2016), RZR® S 900 (2015-2016), RZR® 900 Trail (2015-2015),
RZR® 900 XC (2015-2016)
Removal
1. Remove the screws from the plastic rear fascia. Slowly be in to pull the rear fascia away from
the machine. When there is enou h room, reach in and disconnect the tail light harness. Set the
rear fascia aside.
2. Usin a lon piece of electrical wire or a sprin puller, remove the 2 sprin s at the head pipe-to-
silencer joint and the 2 sprin s that hold the silencer a ainst the frame. Slowly pull back on the
silencer to remove it. Note: You can remove the 2 rubber mounts from the frame as they will
not be reused.
3. Remove the top nut from the rear transmission mount.
. For slip on: Move on to step 1 of HMF Slip on exhaust installation.
For full system: Move on to step 5.
5. Remove the followin :
Seats, Air intake housin , Rear close off panel, Head pipe
6. Carefully remove any asket material left on the cylinder head.
Installation
1. Install the HMF silencer bracket usin the top transmission mount stud and ori inal nut, and
the supplied M8 20 hex bolts, fender washers, M8 nyloc nuts and flat washers.
Note: We have found that some frames have a hole under the plastic (leftmost arrow) and some will
have a hole where the middle arrow is. Use whichever mountin hole is present on your frame. All
will have the hole where the arrow on the ri ht is pointin .

2. Inspect the original donut gasket for wear or dama e and replace it with a new one if necessary.
3. Remove the lower rear facia brackets. Your HMF exhaust comes with replacement brackets.
4. Usin the ori inal mountin bolts, install the HMF replacement rear facia brackets.

5. Install the HMF slip on exhaust usin the fender washers, M8 0 hex bolts, flat washers,
and nylock nuts.
6. Usin a lon piece of wire or sprin puller, install 2 of the original springs at the headpipe-to-
inlet joint.
7. Apply the supplied adhesive heat shield material to the inside of the rear facia, near the exhaust
inlet.

8. Replace rear facia. Remember to plu in the tail light harness and be sure that the harness is
tied away from the exhaust.
9. Inspect all areas around the exhaust system for proper clearance and ali nment. Adjust as
necessary.
Dual Full System Exhaust Instructions
For Models: RZR® 4 900 (2015-2016), RZR® S 900 (2015-2016), RZR® 900 Trail (2015-2015),
RZR® 900 XC (2015-2016)
Removal
1. Remove the screws from the plastic rear fascia. Slowly be in to pull the rear fascia away from
the machine. When there is enou h room, reach in and disconnect the tail light harness. Set the
rear fascia aside.
2. Usin a lon piece of electrical wire or a sprin puller, remove the 2 sprin s at the head pipe-to-
silencer joint and the 2 sprin s that hold the silencer a ainst the frame. Slowly pull back on the
silencer to remove it. Note: You can remove the 2 rubber mounts from the frame as they will
not be reused.
3. Remove the top nut from the rear transmission mount.

. For slip on: Move on to step 1 of HMF Slip on exhaust installation.
For full system: Move on to step 5.
5. Unplu the O2 sensor from the wirin harness.
6. Remove the followin :
Seats, Air intake housin , Rear close off panel, Head pipe
6. Carefully remove any asket material left on the cylinder head.
Installation
1. Be sure cylinder head gasket mating surface is clean from old asket material.
2. Usin the supplied gasket and ori inal mountin bolts, install the new HMF head pipe.
3. Install the HMF silencer bracket usin the top transmission mount stud and ori inal nut, and
the supplied M8 20 hex bolts, fender washers, M8 nyloc nuts and flat washers.
Note: We have found that some frames have a hole under the plastic (leftmost arrow) and some will
have a hole where the middle arrow is. Use whichever mountin hole is present on your frame. All
will have the hole where the arrow on the ri ht is pointin .

4. Slide the “S” bend for the lower silencer over the lower collector outlet on the head pipe.
5. Slide the lower silencer onto the lower “S” bend. Once the silencer is in position, insert 2
Supplied M8x20 Bolts and flat washers in throu h the back of the mounting bracket. Install the
supplied M8 nyloc nuts and flat washers.
6. With the lower silencer level, ti hten up the nuts and bolts for the lower silencer.
7. Slide the “S” bend for the top silencer over the top collector outlet on the head pipe.
8. Slide the top silencer onto the top “S” bend. Once the silencer is in position, insert 2 Supplied
M8x20 Bolts and flat washers in throu h the back of the mountin bracket. Install the supplied
M8 nyloc nuts and flat washers.

9. With the top silencer level, ti hten up the nuts and bolts for the top silencer.
10. Use a sprin puller or lon piece of electrical wire to install the supplied sprin s at the
Collector to “S” bend joints and also at the “S” bend to silencer joints.

11. Replace all body panels and fasteners and check all areas around the exhaust system for proper
clearance and ali nment.
ATTENTION! Improper fuel tunin can cause dama e to your en ine and exhaust. HMF is not
responsible for this type of dama e.
Defender Rear Bumper, Polaris RZR 4 900
Instructions
For Models: RZR® 4 900 (2015-2016)
Installation
1. Drill the top existing mount holes in the frame to 3/8”. Note: It may be necessary to remove
the muffler to access the right side holes with your drill.

2. Pop the knockouts out of the rear fascia. These snap in and out of place and can be removed by
ently pullin back on them.
3. Gently tap the very bottom of the heat shield to bend it in toward the muffler. This will create
clearance between the heat shield and your new rear bumper.
4. Slide the top tubes of the bumper throu h the holes in the rear fascia while linin up
the bottom mounting plate with the existing threaded holes in the frame on either side of the
hitch.
5. Start the 2 10MM Allen head bolts at the bottom bracket. DO NOT TIGHTEN YET.
6. To make installation easier we have included 2 brackets with nuts welded to them for the top
mounts. Hold the bracket inside the left square frame tube where you drilled the holes earlier and
insert the included 8MM bolts with flat washers. DO NOT TIGHTEN.
7. Repeat this step for the ri ht side. You may find it easier to have a helper reach in above the
muffler from the LEFT side to hold the nut bracket in place while you insert the bolts and washers
from the ri ht side. Note: he heat shield on the muffler is sharp. Be careful to avoid cuts when

working around it.
8. Once all bolts are started you can be in to ti hten them. Take a step back and check for proper
ali nment and clearance. Adjust as necessary and finish ti htenin six bolts.
Apex Intrusion Bar, Polaris RZR 4 900
Instructions
For Models: RZR® 4 900 (2015-2016)
Installation
1. Slide the Apex Windshield Bar into position on the Cage.

2. Install Cage Clamps usin the M6x20 Bolts, and ti hten in criss-cross pattern
Spare Tire Rack, Polaris RZR 4 900
Instructions
For Models: RZR® 4 900 (2015-2016)
Installation
1. Usin the supplied Lug Nuts, mount your Spare Wheel and Tire onto the Spare Tire Holder.
2. Determine the Spare Tire Rack orientation in the car o area.
3. Loosely mount the 1-3/ " Tube Clamp onto the harness bar.
4. Ti hten the ( ) Allen Bolts in a criss-cross pattern.

5. Place the white IQ Sticker on the Spare Tire Rack.

Mustang Dynamometer Test Report
00
Date Printed : 2016/03/04 Filter Mode : FIR
Time Printed : 09:09:58 Filter Value : 75
Run# License Owner Acquired Test Comments
1 GLEE OHIO, A 02/25 15:12:43 STOCK
2 GLEE OHIO, A 02/26 09:16:04 XL S/O OPTIMIZER
3 GLEE OHIO, A 02/24 14:19:52 HMF FULL DUAL WITH QUIET CORES OPTIMIZER
Eng Torque T WC Eng Power T WC
13
17
21
25
29
32
36
40
44
48
51
30
36
41
47
52
58
63
69
74
80
85
Speed
6 11 17 22 28 33 38 44 49 55 60
Min Max Avg
Channel / Run 1 1 12 2 23 3 3
Eng Torque T WC (Ft-Lb 15 50 4413 50 4415 51 46
Eng Power T WC (HP) 15 76 6814 78 6814 79 70
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