Fat Boy 4 Complete Exhaust System-Polaris Outlaw 525

MODEL: 2007 Polaris Outlaw 525


1. Remove stock exhaust system; (removal of rear fender is optional) do not remove the steel exhaust manifold that is bolted to the cylinder head. Retain (2) OEM header springs. New muffler bolt(s) are included with Fat Boy 4. NOTE: The rubber grommets (in rear of frame, under seat) that the stock muffler tabs slide into, must be removed to make room for the supplied 10mm muffler bolts to be used.

2. Before starting your Fat Boy 4 installation make sure that the steel exhaust manifold is tight.

3. Slide Fat Boy 4 header onto exhaust flange and attach (1) spring.

4. Install muffler and tail pipe assembly. Before installing, apply a fine coat of Hi-Temp silicone in the front side of the tail pipe. Install supplied bolts (10mm x 30mm) into the top rear muffler mount. After both bolts are installed, tighten both evenly.

5. Install (1) remaining OEM header spring.

6. Check exhaust system front to back that all components are clear. Make sure header springs are secured properly and muffler bolts are secure.

7. After install is complete, install the enclosed rubber strip on the bottom of the right side radiator hose coming off the cylinder. The rubber protector is to be secured via the enclosed zip ties. Make sure the protector is installed on the bottom side of radiator hose between Fat Boy 4 header and radiator hose.

8. JETTING MUST BE CHANGED. Before reinstalling side panel it is recommended to change carburetor jetting. Following are some jetting recommendations.

9. Additional Performance and Jetting Recommendations;
For the best performance using your NEW Fat Boy 4 it is recommended to use a Pro Flow Air Cleaner Kit with either a K&N or Uni air filter. The K&N filter makes the best power. DRI recommends to run machine with air box the lid removed.

DRI has supplied with this instruction packet the necessary pilot and main jets to adjust your jetting.

Jetting Recommendations:
The following guidelines are for Fat Boy 4 equipped 525 Outlaws with the following type set-ups:

Sea Level Temperature between 60° and 90°

Stock Engine Pro Flow Kit with K&N Air Filter with Lid Removed.

Pilots #48
Needle Stock #3
Main Jet: #160

The above specs should be an excellent starting point for most installations.
Jetting should check after install.

DR offers an included jet kit that has required jets for initial set up.

Be careful not to run machine to lean-engine damage may result. To rich power will be lost.

Jetting Notes:

Colder temperature requires richer settings.
Higher elevations cause engine to be low on compression and generally require leaner settings.
Air box lid on requires leaner settings than with lid off.

WARRANTY CARD. MAKE SURE TO FILL OUT THE ENCLOSED WARRANTY CARD AND RETURN TO DRI. FAILURE TO TURN IN WARRANTY CARD CAN VOID ALL WARRANTIES.

For more information contact:

Duncan Racing International, Inc.
10734 Kenney Street Suite A
Santee, CA 92071
USA
(619) 258-6306

Check our Website for additional Polaris Outlaw 525 Performance items.
www.duncanracing.com