The internal combustion engine is really quite simple when you break it all down. It is basically just a mixture of fuel, compression, spark and air forced in one way and out the other. Getting more horsepower out of it is a matter of increasing things from one direction to the other and there are many ways to do so. One of those ways, and a popular one for the Polaris RZR at that, is by bolting on a different exhaust system. Bolting on a new exhaust opens up the airflow of your RZR and adds a custom look and sound, so you get a cosmetic as well as performance boost. With so many different exhaust systems available, it can be hard to select the right one, but we’re here to help. Here are five of the best Polaris RZR exhaust systems available from the aftermarket today.

HMF Racing Performance Series Dual Exhaust System

HMF RZR Exhaust

One of the biggest names in four-stroke exhaust is HMF racing. HMF makes performance systems for many ATVs and side-by-sides. Its Performance Dual System for the RZR adds, on average, 9-11 horsepower and up to 7 lbs-ft of torque at the rear wheel. Being aluminum, the silencers add a significant weight savings over the steel stock exhaust, but you need to keep in mind that you’re also looking at a 6-8 decibel increase in sound output, too. You can lower the decibel level increase with HMF’s Quiet Core add-ons. The system includes USFS-approved spark arrestors. You’ll need to retune the fuel system to match the exhaust system, too.

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Yoshimura R-77 Stainless/Stainless Slip-On

Yoshimura RZR Exhaust

Yoshimira is another big-name exhaust manufacturer and it makes a sweet system for the Polaris RZR. The Yoshimura R-77 system is 20-gauge 304 Stainless Steel and is a direct slip-on exhaust. They are CNC machined and robot-welded for perfect uniformity. USFS-approved spark arrestors are installed and thanks to Yoshimira’s muffler-packing materials, it maintains performance while still meeting USFS noise restriction levels. That is pretty much unheard of with performance exhaust systems. It is also one of the more economical options.

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Trinity Racing Stage 5 Dual Exhaust System

Trinity RZR Exhaust

Trinity Racing has been in the business of making things faster for decades, and business is good. Its Stage 5 exhaust mates dual aluminum mufflers to 304 stainless pipes with the O2 sensor bung welded on. The system carries a five-year warranty and has USFS-approved spark arrestors built in. With this system, you’re going to gain some loudness, but the horsepower and torque gains are significant according to Trinity. Each exhaust is perfectly matched to your specific machine model, so fit will be flawless, making this one of the best RZR exhaust systems you can find.

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Gibson Black Ceramic Exhaust System

Gibson RZR Exhaust

Gibson is well known for its automotive exhaust systems for cars, trucks and SUVs. It makes a sweet bolt-on exhaust system for your Polaris RZR, too. Available in a couple of finish options, the black ceramic system looks sweet and adds a custom look along with performance. You get up to four additional horses and as much as five foot-pounds of torque. That’ll translate to a few additional miles per hour. The best part is the system meets the 96dB threshold for sound. Unlike some systems, the muffler has no packing, so the sound and performance levels stay consistent.

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Big Gun EXO Series Exhaust

Big Gun RZR Exhaust

When you need to make some power, you bring out the Big Gun. Big Gun makes premium four-stroke RZR exhaust systems. It mates a 304 stainless-steel header pipe to a hexagon-shaped, TIG-welded aluminum muffler the shape of the muffler alters the sound waves for a signature Big Gun tone. It has USFS-approved spark-arrestor screens. Expect it to be louder than stock for sure, but also expect to see significant power and torque boosts that Big Gun is known for.

Shop for the Big Gun EXO Series

How much power increase will I get from a RZR exhaust system?

On average, most will see a boost of 3-4 horsepower over stock on most Polaris RZR models, depending, of course, on the engine size and other variables. Torque gets a little more boost and is closer to something that the average driver will feel over the horsepower increase. You will find more power is created with adding the exhaust and doing a fuel management upgrade with a mapping device, something that is recommended by most exhaust manufacturers out there.

What should I be aware of before I change to an aftermarket exhaust on my RZR?

When you add one of these Polaris RZR exhaust systems, you need to know that you’re making a modification that will alter the sound output of your machine. In most cases, it is going to be louder, and in some cases, significantly louder. That can make your machine illegal to use in some riding areas that have noise limits, like National Forests. Also know that if you have added a stereo system, another popular add-on, that you’re going to be competing against yourself for noise levels.

Every RZR exhaust system on this list includes a USFS-approved spark arrestor system. Make sure you have a spark arrestor in the system you choose. You don’t want to be on the hook for starting a forest fire, especially when we’re fighting to keep access open for riding.

Who makes the best Polaris RZR exhaust system?

The best RZR exhaust is the one that you can afford and will work for your riding area and machine. Check the different systems and see which one will fit your machine specifically, and one that matches any future plans you have. No sense buying an exhaust that won’t work well with a future modification plan for a build. Each product on this list has a solid reputation, too, something that can’t be overlooked when planning a build.

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