Installing FMF Q4 Exhaust on Honda CRF250L

Installing FMF Q4 Exhaust on Honda CRF250L

Difficulty: 2/5

Time: 1hr

Tools required:
- 12mm wrenches
- 4, 5mm allen wrenches
- phillips screwdriver
- contact cleaner
- high temp silicone
- WD-40
- medium strength threadlocker fluid

Installing FMF Q4 Exhaust on Honda CRF250L by justdoit248

1. Make sure engine is completely cool prior to installation and the vehicle is in a stable position.
2. Remove the two (2) bolts mounting the heatshield to the muffler.
3. Loosen the band clamp connecting the muffler midpipe to the header.
4. Remove the bolt attaching the midpipe to the subframe; keep for later use.
5. While holding the muffler, loosen and remove the muffler mounting nut and bolt; save the nut for future use.
6. Gently slide the muffler rearward to release it from the header. Use WD-40 in the midpipe/header
junction to help ease removal.
7. Loosen the header flange hardware at the exhaust port to allow the header to rotate if necessary when mounting your new muffler.
8a. If installing the muffler onto a stock header, remove the preinstalled sleeve from the inlet end of the midpipe and apply a light bead of silicone to the inside of the midpipe where the sleeve slides in.
Reinsert the sleeve and wipe off any excess silicone.
8b. If installing the muffler onto an FMF header, remove the sleeve; it is not needed.
9. Using contact cleaner, clean the section of the header where the midpipe connects and allow to dry.
Apply a light bead of high temp silicone for an improved seal.
10. Remove the white side panel from the black heatshield by removing the four (4) phillips head screws.
11. Using the four (4) screws removed in step #10, attach the white side panel to the supplied side panel support (fig. 1).
12. Slide the FMF muffler onto the header. Wipe away any excess silicone.
13. Using the stock bolt removed in step #4, attach the midpipe to the subframe. Do not fully tighten at this time.
14. Insert the supplied 8x45mm bolt first through the frame from the back then through the muffler mount.
15. Slide the supplied washer onto the supplied 1/4x28 bolt then insert through the hole in the side panel support so the head of the bolt is accessible through the slot in the side panel (fig. 1). Apply a small
amount of threadlocker fluid to the threads on the bolt.
16. Loosely thread the 1/4x28 bolt into the mounting boss on the muffler before positioning the side panel support over the muffler mounting bolt. Loosely thread the stock muffler mounting nut removed in step #5 onto the muffler bolt (fig. 1).
17. Adjust the side panel to have adequate clearance to the adjacent panels – note left side panels for reference. Tighten the 1/4x28 bolt to 11 Nm (8ft-lb).
18. Make sure the header and muffler are in a neutral position and not binding. Slowly tighten all mounting fasteners and clamps to manufacturer’s specifications starting at the header flange and finishing at the
muffler mount.
19. 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.