Honda TRX 450 Duals PDF Installation Instruction

Remove stock slip-on and header. Remove rear plastic. Remove stock air box and snorkel. Unbolt your stock regulator from the left side of the frame. This bracket that is welded to the frame needs to be removed. (This process is easily done with a disc cutter). The regulator will re-mount to the air box mounting tabs.

JETTING

Rotate the carburetor clockwise (when sitting on the ATV) remove the hex nut on the bottom of the float bowl. Replace the stock main jet with the supplied (185) main jet. Replace the hex nut and re-mount the carburetor to the manifold.

EXHAUST MOUNTING

Mount the “Y” manifold to the cylinder leaving the nuts a little loose so you can rotate for best fit. Slide both clamps over the ends of the manifold. Install the right pipe from the rear of the ATV between the shock and the frame and slip it over the manifold. Attach the bracket on the inside of the fender and the heel guard brackets. Mount to this location with the supplied 6 x 25 mm bolt, flat and lock washer. Spray a little WD-40 on the end of the chamber, slide the right hand silencer into the chamber. Mount the silencer bracket to the rear fender support bracket with the supplied 6 x 40 mm bolt, flat and lock washer. (Leave hardware off of silencer bracket until you mount the other pipe and re-install your plastic).

Before you mount the left pipe you need to remove the chain guard temporarily for installation. Slide the left chamber in from the rear of the frame and slide it over the manifold, pull the rear of the chamber through the frame and mount to the upper hole behind the heel guard support bracket with the supplied 6 x 25 mm bolt, flat and lock washer. Install the silencer in the same manor as the right side leaving the hardware off the bracket. Re-install the air box and snorkel. Mount the regulator on the outside of the left side mounting bracket with supplied 6 x 25 mm bolt, flat and lock washer.

Re-install your rear plastic as it was removed. Use the supplied hardware to mount the silencers to the rear fender bracket. Tighten the cylinder nuts, then the t-bolt clamp, and then the rear frame brackets. Re-install your chain guard. The cluster of wires and cables that run from the left side of the cylinder up to the radiator need to be pulled down a little and attached to the electric fan housing with the supplied zip tie. (Be sure
the zip tie does not restrict the fan movement). Remove you air box lid, and check that no wires or hoses are touching the pipe. (If they are zip tie the back).

Download Honda TRX 450 Duals PDF Installation Instruction