18033 S Santa Fe Ave. Rancho Dominguez, CA 90221PH: 310.631.4363 FX: 310.900.5699 www.fmfracing.com

Honda XR600 PowerCore 4 S/A MufflerThank you for purchasing the FMF PowerCore 4 S/A muffler for your XR600. We have spent countless

hours of design work and testing to insure you receive the highest quality product on the market today.Your PowerCore 4 has been developed using the latest design, testing and manufacturing technologies. It

has been designed to broaden your existing powerband, increase horsepower and torque throughout the entirepower curve while reducing weight and giving it that mellow factory tone you desire.

Check out our website for more product information including dyno charts and images.

DIMETINOITPIRCSED.YTQ1 PowerCore 4 Muffler N/A1 Long Strap Bracket 9403261 Short Strap Bracket 9403242 Strap Bracket Rubber Sleeves 9004461 #58 Exhaust Band Clamp 9400841 6mm x 12mm Flange Bolt 9210251 6mm Flange Nut 9201401 6mm x 45mm Bolt 9201601 8mm x 30mm Flange Bolt 9201671 19 x 6.4 x 7.6mm Spacer 9200951 19 x 8.4 x 6.4mm Spacer 9200981 11mm x 9mm x 6mm Spacer 940056

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PARTS SUPPLIED 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 heldresponsible for problems derived from improper installation and/or improper usage. Before you begininstalling this product, be sure to wear eye protection and gloves. You should have a completeunderstanding of how to remove and replace the exhaust system. If you do not, you should have itinstalled by a professional mechanic. Keep all OEM parts when removing your stock exhaust as someparts may be utilized with the FMF exhaust depending on your particular application.

INSTALLATION INSTRUCTIONS1. Make sure the bike is completely cool prior to installation and the bike is in a secure position.2. Remove the right plastic side panel to gain access to the muffler.3. Loosen the OEM header clamp at the front of the muffler.4. Slightly loosen the header flanges at the front of the motor.5. Loosen and remove the front OEM muffler bolt. Keep for later use.6. While supporting the muffler, loosen and remove the rear OEM muffler bolt.7. Gently slide the muffler rearward to release it from the header. Spay WD-40 on the joint if it is difficult to

remove.8. Install the rubber sleeves onto the strap brackets so that the rubber is facing inward. make sure the outer

lip is over the bracket edge fully. No rubber should be in the area where the bracket tabs pinch together.9. Clean the header where the muffler slips over with contact cleaner.10. Lightly coat the header where the muffler slips over with hi-temp silicon to aid sealing.11. Slip the header band clamp onto the front of the muffler. Do not fully tighten at this time.12. Slip the muffler inlet over the header until it is fully seated.13. Using the existing OEM bolt, attach the exhaust to the front lower mount. Do not fully tighten at this time.14. Slide the short strap bracket carefully over the muffler and position it to the front upper mounting point.

Be careful not to scratch the aluminum canister and make sure the “inside” sticker on the bracket is towards the subframe.

15. Using vise grip pliers, pinch the strap bracket tabs together and attach using the supplied 8mm x 30mm bolt with the 19mm x 6mm aluminum spacer between the subframe and the strap bracket. Do not fully tighten at this time.

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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.

ATTENTIONThis product is designed for closed course use only unless otherwise stated and not intended to meet emission regulationsfor use on public lands, roads, or access routes - consult with local jurisdictions.

16. Using a 6mm allen wrench, remove the screw from the rear of the fender support that attaches to the rearfender.17. Insert the 11mm x 9mm steel spacer into the rear fender support hole.

18. Slide the long strap bracket carefully over the muffler and position it to the rear fender support mounting point. Be careful not to scratch the aluminum canister and make sure the “inside” sticker on the bracket is towards the subframe.

19. Using vise grip pliers, pinch the strap bracket tabs together and attach using the supplied 6mm x 45mm bolt in the upper strap bracket hole with the 19mm x 7.5mm aluminum spacer between the subframe and the strap bracket. Do not fully tighten at this time.

20. Install the 6mm x 12mm bolt in the strap bracket lower hole using the 6mm nut.21. Slowly tighten all mounting fasteners and clamps to OEM specified torque specs, starting from them

header and working back. Make sure the header and muffler are in neutral positions and not binding.22. Re-install the plastic side panel and any other necessary components.23. Inspect the complete exhaust to make sure the exhaust system is not in contact with the frame, shock

spring, wheel, 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 the manufacturer’s specifications.

24. Before operating your XR600, we recommend using a 155-158 main jet, 65-68 pilot jet with the needle in the 4th clip position and removing the snorkel from the top of the airbox lid. On 1998-2000 models you will need to replace the intake manifold with the 1997 version, as it is too restrictive. Our sea-level, 70 degree, jetting recommendations are to be used as a guide only. There are too many variables outside of FMF’s control to give you an exact configuration. If you’re not capable of tuning your motorcycle yourself, please find a mechanic in your area who is capable to take on this role. Refer to our website for more jetting information.

25. Clean the entire exhaust to remove all dirt and oil residue. This will prevent staining of the materials when it heats up. Windex or 409 works really well to prevent streaking.

26. Start the engine and bring it up to operating temperature. Check for exhaust leaks.27. Let engine cool completely and re-torque all mounting hardware to the manufacturers specifications.

MAINTENANCE & CARE+ To clean your FMF muffler, use soap & water when it becomes dirty. Windex or 409 works great on the muffler canister toprevent streaking and uneven discoloration. Let the exhaust completely cool prior to cleaning. Dry completely afterwards.+ We recommend re-packing your muffler every 20-30 hours depending on the type of riding you’re doing. This will maintain peak performance and keep the sound level from becoming too loud and/or raspy. If sound level changes significantly or your muffler canister shows sign of discoloration, this is a sign to inspect the packing material and replace ifneeded.+ We recommend cleaning the spark arrestor screen every 30 hours of use using a wire brush gently.+ For detailed instructions on how to re-pack your FMF muffler, please visit our website www.fmfracing.com.

Insert steel spacer in rear fender support.