Polaris 2016 RZR 4 900, 2015 RZR 4 900, 2015 RZR S 900, 2016 RZR S 900, 2015 RZR 900 Trail Instructions 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 begin to pull the rear fascia away from
the machine. When there is enough room, reach in and disconnect the tail light harness. Set the
rear fascia aside.

2. Using a long piece of electrical wire or a spring puller, remove the 2 springs at the head pipe-to-
silencer joint and the 2 springs that hold the silencer against 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.

4. 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 following:

Seats, Air intake housing, Rear close off panel, Head pipe

6. Carefully remove any gasket material left on the cylinder head.

Installation

1. Install the HMF silencer bracket using the top transmission mount stud and original 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 mounting hole is present on your frame. All
will have the hole where the arrow on the right is pointing.

2. Inspect the original donut gasket for wear or damage and replace it with a new one if necessary.

3. Remove the lower rear facia brackets. Your HMF exhaust comes with replacement brackets.

4. Using the original mounting bolts, install the HMF replacement rear facia brackets.

5. Install the HMF slip on exhaust using the 4 fender washers, M8 40 hex bolts, flat washers,
and nylock nuts.

6. Using a long piece of wire or spring 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 plug 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 alignment. 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 begin to pull the rear fascia away from
the machine. When there is enough room, reach in and disconnect the tail light harness. Set the
rear fascia aside.

2. Using a long piece of electrical wire or a spring puller, remove the 2 springs at the head pipe-to-
silencer joint and the 2 springs that hold the silencer against 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.

4. For slip on: Move on to step 1 of HMF Slip on exhaust installation.

For full system: Move on to step 5.

5. Unplug the O2 sensor from the wiring harness.

6. Remove the following:

Seats, Air intake housing, Rear close off panel, Head pipe

6. Carefully remove any gasket material left on the cylinder head.

Installation

1. Be sure cylinder head gasket mating surface is clean from old gasket material.

2. Using the supplied gasket and original mounting bolts, install the new HMF head pipe.

3. Install the HMF silencer bracket using the top transmission mount stud and original 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 mounting hole is present on your frame. All
will have the hole where the arrow on the right is pointing.

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 through the back of the mounting bracket. Install the
supplied M8 nyloc nuts and flat washers.

6. With the lower silencer level, tighten 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 through the back of the mounting bracket. Install the supplied
M8 nyloc nuts and flat washers.

9. With the top silencer level, tighten up the nuts and bolts for the top silencer.

10. Use a spring puller or long piece of electrical wire to install the supplied springs 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 alignment.

ATTENTION! Improper fuel tuning can cause damage to your engine and exhaust. HMF is not
responsible for this type of damage.

Defender Rear Bumper, Polaris RZR® 4 900
Instructions

For Models: RZR® 4 900 (2015-2016)

Installation

1. Drill the top 4 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
gently pulling 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 through the holes in the rear fascia while lining 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 right 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 right side. Note: The heat shield on the muffler is sharp. Be careful to avoid cuts when

working around it.

8. Once all bolts are started you can begin to tighten them. Take a step back and check for proper
alignment and clearance. Adjust as necessary and finish tightening 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 using the M6x20 Bolts, and tighten in criss-cross pattern

Spare Tire Rack, Polaris RZR® 4 900
Instructions

For Models: RZR® 4 900 (2015-2016)

Installation

1. Using the supplied Lug Nuts, mount your Spare Wheel and Tire onto the Spare Tire Holder.

2. Determine the Spare Tire Rack orientation in the cargo area.

3. Loosely mount the 1-3/4" Tube Clamp onto the harness bar.

4. Tighten the (4) 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

51

48

44

40

36

32

29

25

85

80

74

69

63

58

52

47

21

17

13

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

Choose HMF Engineering products for superior durability and versatility. Choose reliable UTV accessories and parts offered on our website.

Speed

41

36

30