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High Lifter Looney Tuned Standard Dual Exhaust for Polaris RZR 800 (09-10) User Manual

High Lifter Hardware

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“09” POLARIS RZR INSTALLATION INSTRUCTIONS

PLEASE READ INSTRUCTIONS BEFORE ATTEMPTING INSTALLATION

Kit includes

1 Dual aluminum flange

1 1 piece left pipe

1 2 piece right pipe

1 2 piece silencer bracket

1 Right Silencer

1 Left silencer

2 Quiet cores

2 Port couplers

2 Spark Arrestors

1 Bed Heat Shield

Hardware Kit:
1 - fuel injection controller – if ordered

2 - 8 x 25mm bolts

6 – springs

10 - 5/16 flat washers

4 - spring clips (in hardware kit)

1 - 5/16 lock washer

2 - 8 x 60mm bolts

5 - 8mm nyloc nuts

1 - 8 x 40mm bolts

1 - 8mm male/female rubber mount

2 - spring clips already on silencers

2 - 3/8 Flat washers

2 - 10 x 70 Bolts

1 - Fuel Rail

2 - 1 x ¼ x 7/16 hole spacer

2 - Clamps

1 - XL Heat Shield

2 - HS Brackets

1 – ¼-20 x ½” long bolt w/ flat & lock washer 2 - Quiet Cores (if ordered)
2 - ¼ - 20 x ½” w/flat & lock washer

2 - ¼ flat washer



REMOVAL:

You will have to remove the following items to install your new Looney Tuned Exhaust system.

Remove both seats, and then the four screws behind the seat, the four bolts in the center of the bed, then
the four screws around the tailpipe, the 3 push pins on each side of the bed, next unplug the tail light
connector underneath the left side of the bed and carefully remove the bed from the UTV. Then remove
the complete stock exhaust and retain the flange bolts, the stock port gasket, the stock springs and rubber
bumpers attached to the stock exhaust, remove the stock heat shield to be re-installed onto your new pipe.

INSTALL:

Install your new billet flange with the port couplers installed and attach to the cylinder using your

stock flange bolts (place 1 spring tab and lock washer onto each bolt before threading through the flange
and into the cylinder. See pic 1). Torque to 13 ft lbs. Locate the stock heat shield removed earlier from
your stock exhaust, turn it upside down and re-install it onto your new pipe. (See pic#2) Install the one
piece pipe into the front cylinder port coupler by sliding it through from the passenger side of the UTV
and underneath the bed frame (see pic 2).

Install the header portion of the remaining pipe into the rear cylinder port coupler and attach to

the other pipe via the welded tabs and supplied bolt, flat and lock washer. Install all four springs from the
headers to the flange (see pic # 1 ).

Locate remaining mid pipe and male/female rubber mount. Install the rubber mount onto the mid

pipe bracket and secure with the supplied hardware. Next spray WD-40 onto the slip joint and install the
mid pipe onto the remaining header (see pic#2 ). Attach the supplied bolt, flat and lock washer through
the OEM hole in the frame to the rubber mount.

Spray WD-40 onto the ends of each pipe and slide the silencers on with the Logo facing towards

the outside of the UTV. (See pic#3) Remove the upper rear shock mount “nuts” (do not remove bolts
from the shock), locate the aluminum silencer brackets marked left and right, install onto the rear of the