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18033 S. Santa Fe Ave.
Rancho Dominguez, CA 90221-5514
PH: 310-631-4363
FX: 310-900-5699
www.fmfracing.com
[1-06 / #000706]
YA M A H A R H I N O 6 6 0
PowerLine TM Installation
Thank you for purchasing the FMF PowerLine TM muffler for your Yamaha Rhino. We have spent countless hours of R & D and testing
to ensure you receive the highest quality product on the market today.
All FMF products are developed using the latest design, testing and manufacturing technologies available. We use only the highest quality
materials for function and durability. The PowerLine muffler is a mechanical design specifically engineered for utility ATVs. There is no
packing material to blow out or that would require servicing and the 100% stainless steel construction will not melt through.
The PowerLineTM is a maintenance free muffler that will broaden your existing powerband for an all around power increase without
dramatically increasing the sound level. Bolt on FMF and FEEL THE POWER!
Check out our website www.fmfracing.com for more information.
Please read all instructions thoroughly before installation. Failure to follow all installation instructions completely will void any FMF
warranty implied or otherwise. FMF Racing will not be held responsible for problems derived from improper installation and/or improper
usage. Before you begin installing this product, be sure you are wearing eye protection and gloves. You should have a complete
understanding of how to remove and replace your stock exhaust otherwise have your new FMF muffler installed by a professional mechanic.
Keep all stock hardware when removing your exhaust, as some components may be necessary to install the FMF exhaust depending on your
application.
PA RT S S U P P LI E D
(1) PowerLine Muffler
(2) Strap Bracket
(1) Aluminum Spacer
(1) 8mm Nut
(1) 8mm x 50mm Bolt
044159
940333
920100
920142
921027
(1) 6mm Nut
(1) 6mm x 35mm Bolt
(1) 5/16 x 1-1/4 Washer
(1) Band Clamp
(1) Aluminum Reducer Sleeve
920140
920655
920147
940140
940571
TOOLS REQUIRED
8mm Wrench
10mm Wrench
11mm Wrench
12mm Wrench
Vise Grip Pliers
Contact Cleaner
High Temp Silicone
WD-40®
Spring Puller Tool
Phillips Screwdriver
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
Make sure the engine is completely cool prior to installation and the vehicle is in a stable position.
Lift rear cargo section of vehicle to gain access to the muffler. It is not necessary to remove the rear cargo section but doing
so makes muffler installation easier (refer to the service manual for removal).
Remove the upper heat shield.
Remove the two (2) stock bolts and the straight mounting strap attaching the muffler midpipe to the muffler; keep for reassembly.
Loosen the stock band clamp at the muffler midpipe/header junction.
You will need to remove the header to get the stock muffler out. Remove the four (4) stock nuts attaching the header to the
exhaust ports; keep for reassembly.
Gently slide the header rearward to release it from the exhaust flange and disconnect the header from the midpipe. Use WD-40
in the midpipe/header junction to help ease removal. NOTE - Locate the two (2) copper exhaust gaskets when disconnecting
the header from the exhaust flange and keep for reassembly.
To remove the muffler, loosen and remove the two (2) stock muffler mounting bolts.
P R E - I N S TA L L AT I O N
9a.
9b.
10.
11.
12.
13.
If installing the FMF muffler onto an stock header, insert the aluminum reducer sleeve into the front
of the midpipe inlet until it is fully seated. Use high temp silicone for an improved seal.
If installing the FMF muffler onto an FMF header, the aluminum reducer sleeve is not used.
To re-install the header, the copper exhaust gaskets must be in position. Use a light amount of grease on the cylinder side of
the copper exhaust gaskets to hold them in place on the exhaust flange. Carefully align the header and slide it onto the
flange. Attach header using the four (4) stock nuts and tighten to manufacturer’s specification.
Remove the stock rubber muffler mount and reposition it to be parallel with the muffler by bolting it to the side of the metal
bracket (you are moving it 90 degrees counter-clockwise from original position). Insert the stock bolt through the inside of the
frame bracket with the collar on the rubber mount positioned for the stock nut to be threaded against. The rubber mount will
be pointed forward; do not tighten at this time (see figure 1).
Slide the supplied band clamp onto the midpipe of the FMF muffler; do not tighten at this time.
Using contact cleaner, clean the slip fit section of the header where the muffler midpipe connects. Allow to dry then lightly coat
with a bead of high temp silicone for an improved seal.
I N S TA L L AT I O N
14.
15.
16.
17.
18.
19.
20.
21.
Gently maneuver the FMF muffler into position and slide the midpipe onto the header; wipe away any excess silicone.
To install the first strap bracket, note the “inside” sticker. With the tabs upward, carefully slide strap bracket over the midpipe at
the front of the muffler and slide it into position at the rearward mounting point. Be careful not to scratch the canister and make
sure the “inside” sticker on the bracket is facing inward to the mounting point.
Pinch and hold the strap bracket tabs together making sure the tabs come together approximately 1” to the left of center along
the top of the muffler. Install the supplied 8mm x 50mm bolt through the strap bracket and through the supplied aluminum
spacer, then through the frame bracket fastening with the supplied 8mm nut (see figure 1). Do not fully tighten at this time.
To install the second strap bracket, disregard the “inside” sticker. When in position, the tabs will come together approximately
1” to the right of center along the top of the muffler. With the tabs upward, carefully slide strap bracket over the midpipe at the
front of the muffler and slide it into position at the forward mounting point. Be careful not to scratch the canister.
Pinch and hold the strap bracket tabs together making sure the tabs come together approximately 1” to the right of center along
the top of the muffler. Insert the supplied 6mm x 35mm bolt through the supplied 5/16” washer and through the outside of the
rubber mount, then through the strap bracket with the stock collar between the rubber mount and strap bracket. Fasten bolt with
supplied 6mm nut on the opposite side of the strap bracket (see figure 1). Do not fully tighten at this time.
Fasten the straight mounting strap at the midpipe/header junction with the stock bolts removed in step #4; do not fully tighten at
this time.
Make sure the header and muffler are in neutral positions and not binding. Slowly tighten all mounting fasteners and clamps
to the manufacturer’s specification, starting from the header/midpipe junction and working your way back to the rearmost
muffler mount.
Inspect the complete exhaust to make sure there is no contact with the frame, shock spring, engine, body panels or any
cables, hoses or wiring. The exhaust system should only be in contact with the exhaust port and mounting points. Confirm all
controls operate in accordance with manufacturer’s specifications.
POST-INSTALL ATION
22.
23.
24.
25.
We recommend using high temp silicone for an improved
seal. Please follow instructions for the silicone and allow
sufficient time to dry before starting the engine.
Before operating your vehicle, we recommend either stock
jetting or installing our Power-Up Jet kit for optimum
performance. Our jetting recommendations are to be
used as a guide only and were developed based on
operation at sea-level at 70 degree ambient air
temperature. There are too many variables outside our
control to give you exact specifications. If you’re not
capable of tuning a carburetor yourself, please find a
mechanic in your area. Refer to our website for additional
jetting information.
Start the engine and bring it up to operating temperature.
Check for exhaust leaks.
Let engine cool completely and re-torque all mounting
hardware to manufacturer’s specifications.
Figure 1
MAINTENANCE
To clean your FMF muffler, allow to cool. Do not spray water onto a hot exhaust. Dry completely to prevent streaking. Mild soap and water is
recommended on the muffler canister to reduce streaking and uneven discoloration.
The PowerLine muffler is a mechanical design and has no packing material - it will not require any packing maintenance. The PowerLine does
have a screen type spark arrestor and we recommend cleaning the screen gently with a wire brush after every 30 hours of use.
DISCLAIMER: All products manufactured and/or distributed by FMF Racing are a) intended for use on stock vehicles specific to the U.S. market; b) for closed course use only unless
otherwise stated and c) not intended to meet emission regulations for use on public lands, roads or access routes – consult with local jurisdictions. FMF Racing makes no claims as to
the products applicability, effectiveness or fitment on modified machines. FMF Racing is the sole determines of abuse, misuse, installation errors and modifications. We assume no
liability for any errors in listings, specifications, part numbers, prices or model applications. We reserve the right to change specifications, product descriptions, product quality, pricing
and application at any time without notice and without further obligation. Buyer assumes all risk for any and all damage caused to themselves, a third party and/or property by virtue of
failure of these products. By installing and/or using an FMF product, you hereby accept and understand these stated terms and conditions and have followed all instructional steps.