The Honda Foreman series of all-terrain vehicles covers over three decades of engine and suspension technology. While your Foreman is built to withstand the toughest obstacles in the quickest and easiest ways possible, there comes a time when more power is desired. The best way to increase the performance of your vehicle is by choosing parts that allow your ATV to breathe more consistently. A variety of parts manufacturers and distributors offer exhaust and air filter upgrades for the Foreman. With a little patience and the right tools, installing these new parts in your all-terrain vehicle can be done at home.
Unscrew the bolt that holds the negative terminal of the battery and disconnect the cable attached to it. Loosen the bolts that hold the nuts and bolts of the exhaust manifold to the engine block. Leave the exhaust manifold in place, with the nuts and bolts holding it to the cylinder head.
Unscrew the bolts that hold the tailpipe of the exhaust to the manifold. Unscrew the bolts of the hanging hardware that hold the exhaust pipe from the rear of the bike.
Slide the exhaust pipe out from the manifold and place it to the side. You will dispose of this part eventually, but conventional methods of throwing away trash are not acceptable. Contact your dealer if you need assistance.
Finish loosening the bolts that hold the exhaust manifold to the engine. Slide the old manifold out from the engine and set it aside. Remove the old manifold gasket from the cylinder head and set it aside as well. Both of these parts will need to be disposed of properly.
Scrape any elemental build-up on the cylinder head where the old manifold and gasket rested. Slide the new exhaust manifold gasket into place. The top side should be clearly marked on the replacement gasket.
Position the new exhaust manifold over the newly-installed manifold gasket. Hand-screw each of the nuts and bolts until it is adequately secure.
Slide the new exhaust pipe into the outlet of the new exhaust manifold. Secure the new pipe by installing new bolts into the hanging hardware and reinstalling the bolts that connect it to the exhaust manifold.
Torque the bolts of the exhaust manifold to 11 ft-lbs for factory-specified settings. Reconnect the negative terminal to the engine's battery.
Remove the seat of the Honda Foreman to access the air filter below. Replacing the air filter with an aftermarket, wire-mesh filter can increase the flow of air throughout the engine. These filters are also reusable, so there is no need to replace the filter ever again.
Unscrew the bolts that hold the air filter box together. Remove the top of this filter box to access the old air filter. Pull the old filter out of its position slowly, careful not to drop any of the elemental debris onto the engine.
Clean the area around the air filter thoroughly. It is best to regularly clean this area, as it can severely affect performance in off-road vehicles like the Foreman.
Install the new air filter into place, just as the old one was removed. Although they are aftermarket parts, these wire-mesh filters slide into place very easily.
Close the air filter box and screw in the bolts to secure the filter box. Replace the seat when you are finished.
