Let’s be honest. The stock exhaust on your Polaris General is… adequate. It does its job quietly and without fuss, but where’s the soul? Where’s that throaty rumble that announces your arrival on the trail and the extra grunt you need to conquer that steep, muddy incline?
You’ve probably felt it—that sense that your machine has more to give. You agree that there’s untapped potential just waiting to be released. I promise that upgrading your polaris general exhaust system is one of the most rewarding modifications you can make, transforming not just the sound, but the entire feel and performance of your ride.
In this complete guide from FatBoysOffroad, we’re going to break it all down. We’ll cover the real-world benefits, walk you through choosing the right system, provide a step-by-step installation process, and share essential care tips to keep your new exhaust performing at its best for years to come. Let’s get those wrenches turning.
Why Upgrade Your Polaris General Exhaust System? More Than Just Noise
Many riders think an aftermarket exhaust is just about making more noise. While a killer sound is a huge perk, the real benefits of a polaris general exhaust system upgrade run much deeper. It’s about unlocking the true performance your General was built for.
Unleash Hidden Horsepower and Torque
Your stock exhaust is designed with compromises, prioritizing quiet operation and emissions over raw power. It creates significant backpressure, which is resistance against the flow of exhaust gases.
A well-designed aftermarket system reduces this backpressure, allowing your engine to “exhale” more freely. This improved efficiency translates directly into a noticeable gain in horsepower and torque, giving you better throttle response and more pulling power when you need it most.
Get That Aggressive Sound You Crave
Okay, let’s talk about the sound. An aftermarket exhaust gives your General a deep, aggressive tone that simply can’t be matched by the stock setup. It’s not just about being loud; it’s about a quality sound that reflects the power of your machine.
Whether you want a subtle, deep rumble or a full-on trail-shaking roar, there’s an exhaust system out there that will hit the perfect note for you.
Improve Engine Efficiency and Longevity
By helping your engine breathe better, an upgraded exhaust can actually help it run more efficiently. A more efficient engine often runs cooler and under less strain, which can contribute to a longer, healthier life for your motor. It’s a performance mod that pays dividends in reliability.
Shedding Weight for Better Performance
Stock exhaust systems are typically made from heavy, thick-walled steel. Most aftermarket options use lighter materials like stainless steel or even titanium. Shaving 10-15 pounds off your machine might not sound like much, but reducing weight improves acceleration, braking, and suspension performance.
Understanding the Components: A Polaris General Exhaust System Guide
Before you start shopping, it’s crucial to understand what you’re looking at. Your exhaust isn’t just one pipe; it’s a system of carefully engineered parts working together. Here’s a quick breakdown.
The Header (or Manifold)
This is where it all starts. The header bolts directly to your engine’s cylinder head and is the first component to collect the hot exhaust gases. Aftermarket headers have smoother bends and wider diameter pipes than stock, which is the first step in reducing backpressure.
The Mid-Pipe
As the name suggests, the mid-pipe connects the header to the muffler. It’s a critical piece for routing the exhaust gases toward the rear of the vehicle. In some systems, this pipe may also contain a resonator to help fine-tune the exhaust note.
The Muffler (or Silencer)
This is the big can at the back. The muffler’s job is to reduce the sound volume to acceptable levels using a series of chambers and perforated tubes. The internal design of an aftermarket muffler is what gives it a unique sound and performance characteristic compared to the restrictive stock unit.
Spark Arrestor: A Trail Essential
This is a non-negotiable for off-roading. A spark arrestor is a small screen-like device, usually located at the tip of the muffler, designed to prevent hot sparks from exiting the exhaust and potentially starting a wildfire. Most aftermarket exhausts come with a USFS-approved spark arrestor, but always verify before you ride on public lands.
Choosing the Right Polaris General Exhaust System for You
With so many options on the market, picking the right one can feel overwhelming. Let’s simplify the decision by focusing on three key factors: type, material, and sound.
Slip-On vs. Full System: What’s the Difference?
- Slip-On Systems: These are the most popular and affordable option. A slip-on replaces only the stock muffler, leaving the factory header and mid-pipe in place. It’s a great way to get a better sound and a modest performance boost with a simple installation.
- Full Systems: A full system replaces everything from the cylinder head back—header, mid-pipe, and muffler. This option provides the maximum performance and weight-saving benefits, but it’s more expensive and the installation is more involved.
Material Matters: Stainless Steel vs. Titanium
The material your exhaust is made from affects its durability, weight, and cost.
- Stainless Steel: This is the workhorse of the exhaust world. It offers excellent corrosion resistance, is very strong, and looks great. It’s a fantastic balance of performance and value. Most quality systems are made from 304 stainless.
- Titanium: This is the premium, lightweight option. Titanium is incredibly strong and significantly lighter than steel, but it comes with a much higher price tag. It’s for the rider who wants the absolute best and is willing to pay for it.
- Aluminized Steel: Often found in budget-friendly systems, aluminized steel is a carbon steel coated with aluminum. It offers decent corrosion resistance but won’t last as long as stainless steel, especially in wet or muddy environments.
Considering an Eco-Friendly Polaris General Exhaust System
When we talk about a sustainable polaris general exhaust system, it’s often about two things: durability and emissions. Choosing a high-quality stainless steel system that will last the life of the vehicle is more sustainable than replacing a cheaper system every few years. Additionally, some systems are designed to work efficiently with the stock ECU tune, ensuring the engine runs cleanly and doesn’t waste fuel, which is a key part of being an eco-friendly polaris general exhaust system choice.
How to Install Your Polaris General Exhaust System: A Step-by-Step Guide
Ready to get your hands dirty? This section covers how to polaris general exhaust system installation. While a full system is more complex, the basic principles are the same. Safety first! If you’re not comfortable with any of these steps, there’s no shame in calling a professional mechanic.
Safety First: Pre-Installation Checklist
- Work in a well-ventilated area (exhaust fumes are dangerous).
- Let the vehicle cool down completely. The exhaust gets incredibly hot.
- Wear safety glasses and gloves.
- Use jack stands if you need to lift the vehicle. Never work under a vehicle supported only by a jack.
Tools You’ll Need
- A good metric socket set with extensions and a ratchet.
- Metric combination wrenches.
- A spring puller tool (this is a lifesaver).
- Penetrating oil (like PB Blaster or WD-40) for stubborn bolts.
- Anti-seize compound for reassembly.
- Torque wrench.
Step 1: Removing the Old System
First, you’ll likely need to remove the rear cargo bed or at least tilt it up for access. Start by spraying all exhaust bolts and springs with penetrating oil and let it soak in.
Carefully unhook the springs holding the muffler to the mid-pipe using your spring puller tool. Then, unbolt the muffler mounts from the frame and wiggle the muffler free. For a full system, you’ll repeat this process for the mid-pipe and finally unbolt the header from the engine block.
Step 2: Prepping and Installing the New Header (Full Systems)
If you’re installing a full system, now is the time to install the new header. Always use the new exhaust gaskets provided with your kit. Loosely bolt the new header to the cylinder head. Don’t tighten it all the way yet—you need some wiggle room for alignment.
Step 3: Mounting the New Muffler and Mid-Pipe
Loosely attach the new muffler to the frame mounts. Then, slide the mid-pipe into place, connecting the muffler to the header. Apply a small amount of anti-seize to the bolt threads to prevent them from seizing in the future.
Install the new springs to hold the sections together. This is where that spring puller tool really earns its keep. Make sure everything is aligned properly and not hitting the frame or any other components.
Step 4: Final Tightening, Checks, and First Fire-Up
Now, go back and systematically tighten all the bolts. It’s best practice to start at the header and work your way back to the muffler. Use a torque wrench to tighten the header bolts to the manufacturer’s specification to avoid leaks or damaged threads.
Wipe down the entire system with a clean cloth and some rubbing alcohol to remove any fingerprints or grease. These can burn into the finish when the exhaust heats up for the first time. Re-install your cargo bed, do a final check, and fire it up! Let it run for a few minutes to heat-cycle, then shut it off and let it cool completely. Re-check all hardware for tightness one last time.
Common Problems with Polaris General Exhaust Systems and How to Fix Them
Even the best systems can have issues. Here are some common problems with polaris general exhaust systems and how to troubleshoot them.
Pesky Exhaust Leaks: Finding and Fixing Them
A leak will sound like a ticking or “puffing” noise, especially when the engine is cold. To find it, you can carefully feel for puffs of air around the joints (don’t burn yourself!). The most common culprits are a bad gasket or a loose connection. Tightening the bolts or replacing the gasket usually solves the problem.
Rattles and Vibrations: The Hunt for Loose Hardware
If you hear a new rattle, check your heat shields and mounting brackets first. The vibration of off-roading can loosen bolts over time. A quick check and tighten is usually all that’s needed.
Clogged Spark Arrestor: The Performance Killer
If your General feels sluggish and down on power, a clogged spark arrestor is a likely suspect. Carbon buildup can choke the screen. Most are easily removable with a single screw for cleaning with a wire brush.
Your Polaris General Exhaust System Care Guide for Long-Lasting Performance
You’ve invested in a great upgrade; now let’s keep it that way. Following these polaris general exhaust system best practices will ensure years of trouble-free performance.
Regular Cleaning and Inspection
After a muddy or dusty ride, wash your exhaust system along with the rest of your machine. Letting mud bake onto the pipes can trap moisture and accelerate corrosion, even on stainless steel. While cleaning, give it a quick visual inspection for any cracks or damage.
Checking and Tightening Hardware
About once a month, or after a particularly rough ride, give all the mounting bolts and springs a quick check. As mentioned, vibrations can work things loose over time. A few minutes with a wrench can prevent a bigger headache down the trail.
Maintaining Your Spark Arrestor
Make cleaning your spark arrestor a part of your regular maintenance routine, like an oil change. A clean spark arrestor not only keeps you legal on the trails but also ensures your engine is breathing freely and making full power.
Frequently Asked Questions About Polaris General Exhaust Systems
Do I need a tuner or ECU re-flash after installing a new exhaust?
For a slip-on system, a tuner is generally not required but is often recommended to get the most performance out of the upgrade. For a full exhaust system, a tuner is highly recommended. The significant change in airflow requires adjusting the fuel mapping to prevent the engine from running too lean, which can cause damage.
Will an aftermarket exhaust void my Polaris warranty?
This is a common concern. In the United States, the Magnuson-Moss Warranty Act states that a dealer must prove that your aftermarket part caused the specific failure you’re trying to claim under warranty. However, it’s always best to check with your local dealer, as policies can be interpreted differently.
Are aftermarket exhausts louder than the legal limit?
It depends on the exhaust and your local regulations. Many systems are designed to meet the 96 dB sound limit for off-road vehicles, but some “race” systems are not. Many manufacturers provide dB ratings for their products. Always check your local riding area’s rules before you install a very aggressive system.
You’ve now got the knowledge to choose, install, and maintain the perfect polaris general exhaust system for your machine. This upgrade is about more than just sound; it’s about connecting with your ride on a deeper level and unlocking its full potential. Take your time, follow the steps, and get ready to enjoy a whole new experience on the trail.
Happy wrenching, and ride safe!
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