Kawasaki H2 Magnum Header & Muffler

Remove front cargo bed cover by removing (8) quick rivets. There is a tab underneath the cover holding up against the intercooler cover, you may need to pop the intercooler cover up.

Remove the lower cargo bed by removing (12) quick rivets, (4) cargo tie downs, (4) screws. It helps to remove (4) push darts holding the rear fascia on. Remove bed.

Remove heat shields under the bed by removing (8) Philips head screws and (2) 10mm. Some screws are through-bolted.

Remove the top heat shields on the header. Remove (5) 10mm nuts and washers.

Disconnect the 02 sensor located on the rear of the vehicle. Remove the 02 sensor from the mid pipe. Don’t damage the 02 sensor.

Remove both side muffler hanger brackets from the frame. (4) 14mm bolts.

Remove (2) 14mm exhaust bolts and springs from the connection between the header and side muffler.

Remove (2) 14mm exhaust bolts and springs from the connection between the rear muffler and side muffler.

Remove the side muffler, there is hanger in the front you must slide out of the rubber grommet. Remove both exhaust donuts.

Remove (2) pins holding the rear muffler isolators in place.

Remove both upper and lower heat shields on the header. (6) 10mm nuts and washers.

Remove (10) 10mm nuts holding the header on. (Photo shows lower heat shield on).

Remove the header and (4) OEM exhaust gaskets.

Clean the head surface and install new gaskets or EVP single gasket.

Install the EVP header (without heatshield) Torque exhaust nuts to 15 ft-lb. It is best to heat cycle the header a few times, re-torque the header nuts. Install the heat shield after.

Install the rear muffler into the rubber gromets, reinstall the cotter pins. Align the mid pipe V-band to the header. Leave V-band clamp loose for now. Slip the mid pipe over the muffler entrance. Once all aligned, tighten the clamps.

Wipe the entire exhaust system down with alcohol to remove any fingerprints or debris before first start up.

Reinstall the factory heat shields and plastics in reverse order.