Honda Rancher IRS and Rubicon Full APXUpdated 2 months ago
Please read the below Important Information relating to Safety & Fuel Tuning by clicking on the text below.
Important Information - Safety
WARNING: Before starting the installation of any ATV, UTV, or SXS aftermarket parts, it is important to prioritize safety. Make sure you are using suitable protective gear, this includes but is not limited to safety goggles, gloves and protective clothing.
Ensure your vehicle is on flat, stable ground. Installing parts on uneven or unstable surfaces can potentially lead to injury or damage to the vehicle. The vehicle should be turned off and cooled down before proceeding with the installation. Attempting to install parts on a running or hot vehicle can result in burns or other serious injuries.
After completing installation, it is important to inspect and check the tightness of any and all nuts, screws, and bolts. Failure to properly secure these fasteners can lead to component failure or detachment during riding, posing significant safety risks to both the rider and bystanders. The vehicle should be warmed up and subsequently cooled down to account for any thermal expansion or contraction effects that may affect the tightness of the fasteners.
It is crucial to inspect and tighten screws and bolts as necessary after initial rides, as vibrations and stresses during operation can cause fasteners to loosen over time.
It is important to pay close attention to the condition of the exhaust system and undertake the necessary measures to maintain optimal performance. Failure to properly maintain the exhaust system can result in reduced engine performance and potential safety hazards. Remember to repack exhausts as necessary to ensure efficient exhaust flow and minimize any potential restrictions that could adversely affect performance.
Prior to starting the installation process, it is important to thoroughly read all provided instructions to familiarize yourself with the installation procedures and any specific requirements or precautions. Failure to follow the instructions could result in improper installation or component failure.
Please check your local laws and regulations governing the use of aftermarket parts on your vehicle. Failure to comply with these regulations can result in legal repercussions, fines, or other penalties. Therefore, it is important to research and understand the applicable laws and regulations before installing aftermarket parts on your vehicle. Always ensure that any modifications made to your vehicle comply with local regulations.
Please check and read the full Warranty Information that can be found at:
Important Information - Fuel Tuning
The use of an aftermarket performance exhaust requires a crucial step - EFI tuning. RJWC Powersports exhaust systems must be accompanied by a proper re-flashing or use of an EFI Tuner to prevent the engine from running lean, which can result in engine damage. To guarantee a correct air to fuel mixture, make sure to adhere to the manufacturer’s recommended settings for your fuel tuner.
Neglecting to properly tune the engine using an EFI tuner when using an RJWC Powersports exhaust will void the exhaust warranty. Any problems arising from the engine not running correctly, such as a lean condition or incorrect air/fuel ratio, will not be considered a valid warranty claim.
Please note that if your vehicle differs from the base model, additional modifications such as a different tune, turndown pipe, or other adjustments may be necessary to achieve a proper fit and optimal performance. All RJWC Powersports exhausts are designed and tested on stock-equipped vehicles.
Spark Arrestor & Shim Ring Installation
The Spark Arrestor and Shim Ring are not pre-installed, they can be found in the Hardware Kit.
To install the Spark Arrestor, start by removing the End Tip. Unscrew the four M6x20 Cylinder Screws in the End Tip to remove it.
There is a small circular groove in the End Cap, in this groove you need to place the Shim Ring first, then the Spark Arrestor.
With the Shim Ring and Spark Arrestor in place, reinstall the End Tip by screwing back in the M6x20 Cylinder Screws.
Removing the Stock Exhaust
Remove the side panel to gain access to the header pipe.
Disconnect the header pipe from the cylinder.
Unfasten the bolts/ screws that hold the stock exhaust in place.
Once unfastened, you should be able to simply remove the entire stock exhaust and the header pipe.
Installing the APX Exhaust
Place the G2 Gasket in-between the pipe and the APX can, lining up the holes between all three. Use 3x Hex Flange Screws to secure the top three positions of the of the flange and the G2 Gasket. The bottom two holes should remain unsecured.
Thread the Lower Bracket onto 2 Hex Flange Screws and secure this into the bottom two holes of the flange. The Lower Bracket should point away from the side of the APX can that has the RJWC Logo.
Don't tighten these fully as they may need to be adjusted.
Place the 1x Upper Clamp and 1x Lower Clamp around the front section of the APX exhaust can. Use 2x M5x16 Cylinder Screws and 2x M5 Washers on each side to secure the clamps in place.
Do not tighten the clamps fully, as their positioning may need to be adjusted.
Place the 1x Upper Bracket on the top of the APX Upper Clamp.
Add 1x Washer 8.4 to 1x M8 Screw and use these to secure the Upper Bracket to the APX Upper Clamp.
Check the picture above to make sure you install it facing the right way
Install the new header pipe.
Apply the supplied heatpad to the plastic side panel, where the header pipe comes into the closest proximity with the panel.
Install the Lambda Sensor by using the M18 to M12 Adapter.
To help with the fitment of the header pipe, you can use the provided aluminum ring in-between the gasket and the cylinder.
Install 1x Aluminum Cylinder into the black bracket above where the stock exhaust was previously installed.
Install 1x Aluminum Cylinder into the the black bracket below where the stock exhaust was installed.
While holding the exhaust in place, align the Upper APX Bracket with the frames black bracket and thread an M8 Hexagon Bolt through.
Fasten 1x Aluminum Washer to the ‘inside face’ of the Hexagon Bolt. Secure this in place with 1x M8 Nut.
Repeat Step 7. for the lower black bracket. Use 1x M8 Hexagon Bolt to secure the Lower APX Bracket to the black bracket.
Placing 1x Aluminum Washer and securing with 1x M8 Nut.
Align the header pipe and the exhaust, firmly connecting the header pipe into the exhaust.
Once in place, set the clamp just atop where the two connect and tighten the screw to secure it in place.
With the exhaust mounted you need to tighten all screws in place. You should start your vehicle, allow the exhaust to get warm and shut the machine down to cool. When it is cool, double check all screws and bolts and retighten them.
After your first ride, double check all screws and bolts and retighten.
You have now completed the installation of the Honda Full APX.
If you have any questions, or need any help please send an email to [email protected]