S S 550-1036 Power Tune XTO Exhaust Instruction Manual
- June 4, 2024
- S S
Table of Contents
550-1036 Power Tune XTO Exhaust
Installation Instructions: S &S® Power Tune® XTO Exhaust for
Polaris RZR® Turbo (550-1036)
DISCLAIMER
Many S&S parts are designed for high-performance, closed course, and racing
applications and are intended for the very experienced rider only. The
installation of S&S parts may void or adversely affect your factory warranty.
In addition, such installation and use may violate certain federal, state, and
local laws, rules, and ordinances as well as other laws when used on motor
vehicles used on public highways. Always check federal, state, and local laws
before modifying your motorcycle. It is the sole and exclusive responsibility
of the user to determine the suitability of the product for his or her use,
and the user shall assume all legal, personal injury risk and liability and
all other obligations, duties, and risks associated therewith.
NOT LEGAL FOR SALE OR USE IN CALIFORNIA ON ANY POLLUTION CONTROLLED MOTOR
VEHICLE *Qualified Manufacturer Declared 49-State Federal Emissions Compliant
Exhaust System
SAFE INSTALLATION AND OPERATION RULES
Before installing your new S&S part, it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety.
- Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed. Do not smoke. Perform installation in a well-ventilated area away from open flames or sparks.
- If the motorcycle has been running, wait until the engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps.
- Before performing any installation steps, disconnect the battery to eliminate potential sparks and inadvertent engagement of the starter while working on electrical components.
- Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps. Contact S&S with any questions you may have if any steps are unclear or any abnormalities occur during the installation or operation of a motorcycle with an S&S part on it.
- Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation.
- Use good judgment when performing installation and operating motorcycles. Good judgment begins with a clear head. Don’t let alcohol, drugs, or fatigue impair your judgment. Start installation when you are fresh.
- Be sure all federal, state, and local laws are obeyed with the installation.
- For optimum performance and safety and to minimize potential damage to carb or other components, use all mounting hardware that is provided and follow all installation instructions.
- Motorcycle exhaust fumes are toxic and poisonous and must not be breathed. Run a motorcycle in a well-ventilated area where fumes can dissipate.
IMPORTANT NOTICE:
Statements in this instruction sheet preceded by the following words are of
special significance.
WARNING
This means there is the possibility of injury to yourself or others.
CAUTION
This means there is the possibility of damage to the part or motorcycle.
NOTE
Other information of particular importance has been placed in italics type.
S&S recommends you take special notice of these items.
WARRANTY
All S&S parts are guaranteed to the original purchaser to be free of
manufacturing defects in materials and workmanship for a period of twelve (12)
months from the date of purchase. Merchandise that fails to conform to these
conditions will be repaired or replaced at S&S’s option if the parts are
returned to us by the purchaser within the 12-month warranty period or within
10 days thereafter.
In the event warranty service is required, the original purchaser must call or
write S&S immediately with the problem. Some problems can be rectified by a
telephone call and need no further course of action.
A part that is suspected of being defective must not be replaced by a Dealer
without prior authorization from S&S. If it is deemed necessary for S&S to
make an evaluation to determine whether the part was defective, a return
authorization number must be obtained from S&S. The parts must be packaged
properly so as to not cause further damage and be returned prepaid to S&S with
a copy of the original invoice of purchase and a detailed letter outlining the
nature of the problem, how the part was used and the circumstances at the time
of failure. If after an evaluation has been made by S&S and the part was found
to be defective repair, replacement or refund will be granted.
ADDITIONAL WARRANTY PROVISIONS:
- S&S shall have no obligation in the event an S&S part is modified by any other person or organization.
- S&S shall have no obligation if an S&S part becomes defective in whole or in part as a result of improper installation, improper maintenance, improper use, abnormal operation, or any other misuse or mistreatment of the S&S part.
- S&S shall not be liable for any consequential or incidental damages resulting from the failure of an S&S part, the breach of any warranties, the failure to deliver, delay in delivery, delivery in non-conforming condition, or for any other breach of contract or duty between S&S and a customer.
MUFFLER REMOVAL
-
Remove 4 Torx style fasteners (40 Torx sockets) retaining the rear plastic muffler cover.
-
Remove two muffler springs.
-
Remove the 3 nuts from the header pipe
-
Pull the muffler towards the rear of the vehicle to remove it from the rubber mounting isolators.
-
Remove the stock driver-side muffler cover bracket.
MUFFLER INSTALLATION
-
Install the new drive-side rear muffler cover bracket that comes with your new muffler.
-
Install the muffler mounting studs into the rubber isolators on the chassis.
-
Install a new flange gasket if needed. Put a dab of high temp anti-seize on the studs and install the three nuts on the flanges. Torque nuts to 18 ft-lb (24 Nm)
-
Install the two muffler springs.
-
Install the rear plastic muffler cover. (4 Torx-headed fasteners) Torque 8 ft-lb (11 Nm)
-
Start the Vehicle and check for exhaust leaks
SPARK ARRESTOR CLEANING AND MAINTENANCE
NOTES: A plugged spark arrestor will cause performance loss. Always
replace a cracked or damaged spark arrestor before operating.
The spark arrestor should be cleaned each time the machine is submerged in
water/mud and after every oil change.
- Remove the spark arrestor retaining fasteners.
- Remove the spark arrestor from the end of the muffler.
- Use a non-synthetic brush to clean the screen on the spark arrestor. If necessary, blow debris from the screen with compressed air.
- Inspect the screen for wear and damage. Replace if damaged.
- Reinstall the spark arrestor. Torque fasteners to specification. Torque spark arrestor Fasteners: 8 ft-lb. (11 Nm)
How to change the Power Tune XTO tunable inserts, spark arrestor, and
retaining bulkhead ring
Tools needed
5/32 Allen Wrench
1/8 Allen Wrench
Small pry bar with foot Small Hammer Small punch or flat screwdriver
Removing Inserts
Remove the 3 socket head bolts using the 5/32 Allen wrench.
Tap the edge of the end cap to pop it loose from the outlet tube.
Remove supplied insert and replace it with an optional insert.
Replacing inserts
Put a small amount of anti-seize on the threads of all the bolts.
While holding the insert with one hand, place the end cap over the insert aligning the holes.
To keep the insert and the end cap aligned, place a bolt in only one of the 3 holes.
Now carefully place the assembly over the exhaust outlet tube aligning the bolt to the threaded hole.
Once the first bolt is slightly started into the threads go ahead and start the other two bolts.
Now you can tighten all 3 bolts by doing a circular pattern turning each bolt
2-3 full turns until all three bolts are tight. The reason for that is to pull
the end cap down in an even configuration.
Keep in mind the bolt spacers that are welded to the inside of the end cap can
be out of alignment slightly after the removal process. If this occurs, take a
smaller punch or screwdriver that will fit into the threaded area and
straighten. Using a flashlight to visually align the spacer to the bolt hole
then thread in the bolt. Do this to all until you have
all three bolts started in the threads.
Now that you have customized the sound and power on your Power Tune XTO
Muffler, fire it up and listen and feel the difference.
Check the chart below for sound configurations.
INSERT dB CHART
BOTTOM| 1.| 2.| 1.625″| 1.75″| 1.875″| 2″| 2.| CAP| 3.5MM F| 3.5MM R
TOP| dB levels may slightly vary on different models. Chart below is based on
the 2020 Polaris Pro XP Turbo 4000/6000 RPM
1.| 96.2 -106| 96.2 -106| 96.7-106| 96.7-106| 96.7-106| 97.2-107| 97.2-107|
93.5-104.4| 95-105| 95-105
2.| 96.3-106| 96.3-106| 96.3-106| 96.6-106| 96.8-106| 97-107| 97-107|
93.6-104.3| 96- 106| 96-106
2.| 96.3-106| 96.7-106| 96.8-106| 96.8-106| 96.8-106| 97.3-107| 97.5-107|
93.5-104.3| 95.5-106| 95.4-106
2.| 96.7-106| 96.9-106| 96.8-106| 97.2-107| 97.4-107| 97.5-107| 97.5-107|
94.3-104.5| 95.9-106| 95.9-106
2.| 96.7-106| 96.6-106| 96.7-106| 97.4-107| 97.5-107| 97.5-107| 97.5-107|
94.4-104.6| 95.8-106| 95.8-106
2″| 97.1-107| 97.1-107| 97.3-107| 97.5-107| 97.4-107| 97.5-107| 97.7-107|
94.6-104.5| 95.7-106| 95.8-106
2.| 97.1-107| 97.1-107| 97-107| 97.5-107| 97.6-107| 97.7-107| 98-107|
94.3-104.6| 95.8-106| 95.8-106
CAP| 93.5- 104.4| 93.6- 104.3| 93.6- 104.3| 94.3- 104.5| 94.4- 104.6| 94.6-
104.5| 94.6- 104.6| Do not use| Do not use| Do not use
3.5MM F| 95-105| 95-106| 95.3-106| 95.9-106| 95.8-106| 95.8-106| 95.8-106| Do
not use| Do not use
Do not use| Do not use
Do not use
3.5MM R| 95-105| 95.3-106| 95.4-106| 95.5-106| 95.7-106| 95.8-106| 95.8-106|
Do not use
| Idle at 85| Idle at 82| Idle at 81| Do not use| | | | | |
TEST WAS DONE ACCORDING TO J1287 STANDARDS @4000 RPM AND @6000 RPM
How to change spark arrestor
Removing Inserts
Remove the 3 socket head bolts using the 5/32 Allen wrench.
Tap the edge of the end cap to pop it loose from the outlet tube.
Remove the end cap and insert.
Now remove the rubber plug
Take your 1/8 Allen wrench and remove spark arrestor bolt
The spark arrestor can be removed if the spark arrestor does not come out
easily. You can thread the bolt you just removed into the back side of the
spark arrestor nut and use it as a pulling point.
Using a pry bar or some other tool now you can pull up the spark arrestor and
remove it.
To reinstall the spark arrestor do the steps in reverse order.
Removing bulkhead retaining ring
Follow the steps for removing the end cap
Remove the end cap and insert.
Remove the two bolts holding the retaining ring. 
Remove the bulkhead retaining ring.
To reinstall, do steps in reverse order.
Instruction 510-0862 07-14-2021
Version 2 © 2021 by S &S® Cycle, Inc.
All rights reserved. Printed in the U.S.A.
14025 Cty Hwy G
Viola, Wisconsin 54664
Phone: 608-627-1497
Technical Service Email: sstech@sscycle.com
Website: www.sscycle.com