Gibson 98001 Performance Exhaust Stainless Header and Exhaust System for Polaris Instruction Manual

Gibson 98001 Performance Exhaust Stainless Header and Exhaust System for Polaris

Package Content

Part #98001

BO -1069

| 1| Bolt Kit for
G| RH017| 3| Springs
H| 14025| 2| Radiator Hose Heat wrap 4” x 7”
I| ZIP| 3| Zip Ties for Heat Wrap
J| RHO34| 1| Cylinder head heat shield

Thank you for purchasing our Gibson Exhaust System for your vehicle.
If you need further assistance, please do not hesitate to call our technical department at (800) 528 -3044 Monday through Friday, 8am to 5 pm.

Installation Instructions #98001

When installing this exhaust system make sure to use proper safety precautions. Make sure to set parking brake, block tires and use safety glasses and gloves. Allow exhaust to cool before attempting installation. Severe injury or burns could occur if safety measures are not taken.

Note: The factory Exhaust Springs and Gaskets will be re used in the install of the Gibson Exhaust.
SUGGESTED TOOLS: Needle Nose Pliers,15mm & 12mm wrenches & sockets, WD-40

1. Remove the factory muffler by using the 15mm wrench or socket at the band clamp shown in the photo. Spraying a small amount of WD-40 will help with the removal of muffler from the rubber hangers
   

2. Next remove the entire exhaust. Do not damage the factory springs or Exhaust gaskets as they will be re used.
   

3. Now install Gibson Muffler Item D. Slip the muffler in from the rear of the Rzr. Slip the lower long hangers into the rubber grommets first then pull back and slide the upper hanger into the single rubber grommet.
   

4. You will need to assemble the header and collector before installing onto the Rzr. Item A will be installed onto the front exhaust port. While Item B is the rear exhaust port.
   

5. Use the factory springs to attach Item C to the header pipes. Item C the collector will have a top and a bottom. When looking at the collector from the side one way will have the single exit  facing up wards at about a 10 degree angle or down ward. You want the single exit of the collector facing downward when slipping it onto the header pipes.
   

6. . Slip item E dome gasket onto the outlet of the header collector and install the header assembly intothe Rzr. Adjust the header tubes to allow the flanges to line up properly. Install supplied header bolts and factory gasket. Do not tighten.
   

7. With the header still loose, but the header bolts installed attach the supplied Gibson springs. Use the Needle nose pliers and a small flat head screw driver to assist with the install. It is important to use your safety goggles.
   

8. After springs are installed make sure everything is fitting properly and tighten the header bolts. Now install the supplied heat wrap around the radiator hose seen in the photo.
   

9. Install Cylinder head heat shield item J. Above cylinder head you will find two ½” factory nuts and bolts. Remove nuts an install the heat shield using the factory nuts an bolts. Once installed and in place tighten the factory nuts and bolts.
   

10. After everything is installed make sure everything is clean of all grease and finger before starting the vehicle to maintain a nice clean surface.
    

GIBSON EXHAUST systems are designed on a factory stock vehicle. Any aftermarket products installed could increase the sound levels of the exhaust
Make sure there is a 1” clearance from ALL rubber brake lines, shock boots, lines, tires, etc. to revent heat related

Documents / Resources

| Gibson 98001 Performance Exhaust Stainless Header and Exhaust System for Polaris [pdf] Instruction Manual
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