PERFORMANCE EXHAUST SYSTEM
Contents
1.2. APPLICATION PERFORMANCE EXHAUST SYSTEM YEAR MODEL 2011 2012 Suzuki GSX R600 750 PRODUCT 7160003221 71160003521 1160003551 R77D Stainless Steel Full System Exhaust System with Carbon Fiber Sleeve Carbon Fiber Endcap R77D Stainless Steel Full System Exhaust System with Stainless Steel Sleeve Carbon Fiber Endcap R77D Stainless Steel Full System Exhaust System with Stainless Steel Sleeve Stainless Steel Endcap This product is designed for use in closed course racing and is not intended for highway use n the state of California it is illegal to modify the emission control system which includes the fuel injection of any vehicle You must know how to remove and replace your stock exhaust in order to install this product otherwise have it installed by a professional mechanic Keep all stock parts from your existing system as some components may be necessary to install your new Yoshimura exhaust depending on the application Read through all instructions before beginning installation Exhaust system can be extremely hot Let motorcycle cool down before beginning installation Always wear hand and eye protection and take precautionary measures to avoid injury Noj Pame Desorption Qiy 11600 404 Yoshimura Header a 11600 419 Yoshimura Tailpipe E Yoshimura Muffler CF Sleeve CF Endcap SRR77D126W SS 4 1 1121 MPCA CF Sleeve 1121 MPCAX SS Sleeve HT SHLDR77 Muffler Clamp 1 Heatshield SS Sleeve CF Endcap 1228SMT Yo
3. 3 NOTE After starting motorcycle it is normal for new exhaust system and muffler to emit smoke until oil residue burns off 5420 Daniels Street Chino CA 91710 Tel 800 634 9166 Fax 909 591 2198 www yoshimura rd com 1160003 221 521 551 Page 2 of 4 NECESSARY WIRING CHANGES For 2011 Model Only 1 Itis necessary to properly disable the Suzuki SET Suzuki Exhaust Tuning system by following the steps listed below Without properly disabling the SET system the engine will run in a power limited fail safe mode Remove rider seat and lift fuel tank With ignition in the OFF position disconnect the black wire harness plug from the ECU See Fig 2 Remove the orange cap by pressing the small orange tabs on the side apart and pulling the orange cap off See Fig 3 5 Remove 5 wire Brown Black Stripe by inserting a very small flat head screwdriver into the pin hole and gently pry down to unlock the wire and pull the wire out from the rear of the plug Note If you do not have a small flat head screwdriver you can make one using a regular paper clip See Fig 4 6 Completely seal off the disconnected wire using electrical tape and shrink tube to prevent possible electrical problems Secure disconnected wire to harness using a zip tie Re install orange cap onto black wiring harness plug and re connect plug to ECU Lower fuel tank and re install rider seat Completely remove the exhaust valve cables from the EXCVA
4. ader leg at a time onto manifolds Note Lightly tap header legs with a plastic mallet to ensure a tight fit Connect header to flanges using the supplied springs Install chassis mount bolt to secure header Torque to 16 5 ft lb 23 Nm 2 3 kgf m Slide Yoshimura muffler and tailpipe assembly onto header Install rubber heat insulator onto Yoshimura muffler clamp Slide muffler clamp over muffler and install muffler clamp to the inside of the stock muffler mount bracket using supplied hardware See diagram for orientation Note Twisting of tailpipe may be necessary for proper alignment If needed remove muffler springs to twist tailpipe for proper alignment 7 Install springs on tailpipe to header connection 8 Re install stock O2 sensor onto Yoshimura header 9 Re install radiator bracket Note For GSX R750 use provided Yoshimura radiator bracket N R S FITMENT CHECK amp NOTES 7 Before starting motorcycle check for proper clearance between new exhaust system and rear suspension i e tire swing arm brake rear shock engine and etc If any problem is found please carefully follow through the installation steps again If problem still persists please call Yoshimura Tech Department at 800 634 9166 in CA 909 628 4722 2 Itis recommended that the muffler and tailpipe be wiped down with rubbing alcohol to remove oil and fingerprints This will help prevent tarnishing of the finish after the exhaust is heated up
5. servo Refer to Factory Service Manual for removal instructions Note Do not unplug EXCVA servo as it may cause the bike to run in fail safe mode RAUN O SO N oth pin from the right side Brown Black Stripe Wire 1st row from the top Oo0o0o0o00000000 O00000006666 oOoo0oo0o00000000 Oo0o0o000000000 0 oOoo0oo0oo00000000 Oo0oo0o000000000 Fig 1 Fig 3 Fig 4 5420 Daniels Street Chino CA 91710 Tel 800 634 9166 Fax 909 591 2198 www yoshimura rd com 1160003 221 521 551 Page 3 of 4 EXCVA STOPPER BRACKET INSTALLATION For 2012 Mode Only 1 Remove rider seat and lift fuel tank 2 With the ignition in the OFF position remove the 2 bolts securing servo motor to frame See Fig 5 3 Completely remove exhaust valve cables from the EXCVA servo Refer to Factory Service Manual Note DO NOT turn on the ignition when cables and pulley is removed 4 While securely holding the pulley remove pulley mounting bolt Note Pulley must stay in original position when removing bolt to prevent damage to the internal gear of EXCVA 5 Using the stopper bracket provided in the kit install bracket to EXCVA using stock bolt Torque bolt to 5Nm 0 5kg m 3 5Ib ft See Fig 7 6 Reinstall EXCVA onto frame using the opposite steps of removal Fig 6 Fig 7 5420 Daniels Street Chino CA 91710 Tel 800 634 9166 Fax 909 591 2198 www yoshimura rd com 1160003 221 521 551 Page 4 of 4
6. shimura Manifold ly r r r CRR77D126W SRR77D126W SS Sleeve SS Endcap Muffler Clamp 1170SDY Yoshimura Flange 8 RACE SPX 1 Short Spring 4 9 RACE SPS 1 Medium Spring 8 Soc Head Cap Screw 5420 Daniels Street Chino CA 91710 Tel 800 634 9166 Fax 909 591 2198 www yoshimura rd com 1160003 221 521 551 Page 1 of 4 TOOLS REQUIRED Metric Socket Set Combination Wrench Set Torque Wrench Metric Allen Wrench Set Screwdriver REMOVAL 7 Remove left and right side fairing as per Factory Service Manual 2 Remove stock muffler by loosening exhaust clamp and while securely supporting the muffler remove muffler mount bolt Remove lower radiator support bracket and swing radiator forward to ease removal of stock header Remove O2 sensor from stock header 5 Remove exhaust valve cables NOTE Stock exhaust valve cables will not be used with Yoshimura Full System Exhaust For 2011 model see wiring change For 2012 model see EXCVA stopper installation 6 Carefully remove stock header and exhaust port gaskets Note Yoshimura Full System is designed to be installed without exhaust port gaskets A amp INSTALLATION 7 Install Yoshimura manifolds and flanges into exhaust ports using stock header bolts Torque to 7 3 ft lb 10 Nm 1 0 kgf m See flange orientation below Q e OD O Install Yoshimura header from one end of the engine to the other by slipping one he
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