How to Install a Fastway Spark Arrestor (PMB-01-1105)

Installing a Fastway Spark Arrestor is a straightforward process that converts your stock exhaust into a U.S.F.S. approved spark-arrested muffler. Follow the step-by-step guide below to ensure proper installation and long-term performance.

⚠️ Before You Start

• Read all instructions completely before beginning.
• If you are not comfortable with drilling or exhaust modification, have a qualified technician perform installation.
• You will NOT reuse the stock end cap.

🧰 Tools Required

• 13/64” drill bit
• Drill
• Flathead screwdriver
• Allen wrenches
• Hammer
• Center punch
• High-temp RTV silicone sealant
• Utility knife

🔧 Step 1: Remove Muffler & Stock End Cap

1. Remove the muffler from the bike following manufacturer instructions.
2. Drill out the rivets holding the stock end cap using a 13/64” drill bit.
3. Use a center punch and hammer to push rivets into the muffler.
4. Cut the silicone seal around the end cap.
5. Pull the stock end cap out of the muffler.

Pro Tip: If the end cap is stuck, apply heat to the muffler sleeve to loosen the seal.

🔧 Step 2: Prep the Muffler

1. Remove all leftover rivet debris from inside the muffler.
2. Transfer any fiberglass packing from the stock end cap to the new spark arrestor base.

🔧 Step 3: Install Spark Arrestor Base

1. Apply high-temp RTV silicone around the base (for sealing and vibration control).
2. Insert the spark arrestor base into the muffler.
3. Ensure it is fully seated and flush with the muffler edge.

🔧 Step 4: Secure the Base

1. Drill holes at each original rivet location.
2. Install self-tapping screws one at a time.
3. Keep pressure on the base to ensure a tight fit while securing.

🔧 Step 5: Install Screen & End Cap

1. Insert the spark arrestor screen.
2. Install the end cap/nozzle.
3. Tighten using supplied M6 bolts.

🔧 Step 6: Reinstall Muffler

1. Reinstall the muffler onto the bike.
2. Double-check all bolts and fasteners.

🛠️ Maintenance & Inspection

• Inspect spark arrestor screen regularly.
• Recommended: check during every air filter service or oil change.
• Clean screen to maintain proper airflow and performance.

⚠️ Important Safety Notice

A damaged or clogged spark arrestor will not function properly. If the screen develops holes or excessive buildup, it must be replaced immediately.

💡 Why Install a Spark Arrestor?

• Required for many trail systems and public lands
• Helps prevent wildfires
• Maintains legal compliance for off-road riding

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