How To: DMC Dual Exhaust System for Polaris RZR

Project Weekend Warrior RZR

Oct. 09, 2008 By Dean Waters

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This month we wanted to show you how easy it is to install a dual exhaust system on your Polaris RZR. We contacted DMC about their recently released twin system for the RZR and had one sitting on our doorstep in no time. Along with the dual exhaust system DMC also recommended their EFI module which is tuned to work with this combination. This combination will give the RZR a 21.2% increase in torque while keeping the sound levels to 96 db.

This is the complete DMC system including the EFI controller.

Removal

The first thing you have to do is remove the bed of the RZR. While this sounded like a large task I soon discovered it was actually quite easy. In total I think it took about 20 minutes max to pull the bed off.


Remove the seats for access to the front of the bed.	Remove the 4 bolts at the front of the bed behind the seats. These require a #25 Torx.


Now remove the 4 bolts on the floor of the bed. A 1/2" socket will do the trick here.	Now remove the 4 Torx on the back of the bed.


*Remove the 3 push pins on each side of the bed. These are kinda a pain in the %)* but a straight screw driver will make it relatively easy.**	The only thing left is to disconnect the tail light wiring under the fender above the left rear tire.

Our Polaris RZR with the bed removed.


Remove the exhaust clamp and then the springs allowing you to remove the stock mid-pipe. A spring puller is helpful but some pliers will work.	You may have to wiggle the mid pipe around to get it to slide away from stock silencer.


The stock silencer slips out with the mid-pipe removed.	The only preparation needed is to install the rubber grommets into the new mufflers.

Installation


Now we can start by installing the DMC velocity splitter on the stock header. Re-use the stock springs and make sure the metal gasket stays in place.	Now install the two mid pipes. The left side is the one with only one bend.

Now with the velocity splitter and mid pipes installed you need to re-install the bed. The muffler mount bar attaches with two new bolts that go through the rear holes in the bed. These self tapping bolts will thread through the frame.


With the bed on attach the muffler mount bar with the locking nuts. Don't over tighten them, the bolts are plenty long .......	Now bolt up the mufflers on both sides to the muffler mount bar. Don't tighten them down until everything is in place. Make sure the pipes are not touching any cables, hoses, or the frame and you are done.

EFI Controller Installation


With the seats still out, remove the access panel with the 1/4 turn handles. The EFI / fuel injector connection is on the right side.	Remove the fuel injectors one at a time and plug the EFI controller in-line.


Now connect the black wire to negative terminal of the battery. You are essentially done.	We stuck the Velcro strips on the back of this panel and stuck our controller there where it should have plenty of protection from the elements.

Before installing the seats we fired up the RZR to make sure the controller was installed correctly. If so, the lights will illuminate from side to side for a few seconds then will stop. They will then light up as you rev the motor.

Re-install your seats and your ready to go play. We left the EFI settings as they came as DMC has tuned it for a stock motor with Afterburner exhaust and Pro Design air filter kit.

Summary

The complete installation took us less than a couple hours, and that was taking our time and making notes and taking pictures as we went. It was one of the easiest installations we have done in a long time. The dual afterburners look great and while we were expecting them to be much louder, they really weren't that much louder than stock, and actually have a very nice "purr."

Stay tuned for video demonstration and sound comparison.

RZR with DMC Dual Exhaust