PERFORMANCE EXHAUST SYSTEM
Contents
1. PERFORMANCE EXHAUST SYSTEM YOSHIMURA APPLICATION MAKE MODEL RZR800 5 4 XC PRODUCT 394000G551 RS8 SS Full System Exhaust with Stainless Steel Sleeve Spark Arrested This product is designed for use in closed course racing and is not intended for highway use In 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 vehicle cool down before beginning installation Always wear hand and eye protection and take precautionary measures to avoid injury 0 fG AE a EE 9 Part Description 394000 101 Yoshimura Header 394000 102 Yoshimura Hdr Leg 1 394000 103 Yoshimura Hdr Leg 2 394000 140 Yoshimura Midpipe 394000 144 Yoshimura Tailpipe 394000G551 Yoshimura Muffler 39400 TPBRKT TP Hanger Bracket 39400 BRKT Muffler Hanger Bracket 8MMNUT 8mm Nut Z1022 Rubber Grommet ALS 003 Aluminum Spacer M8X30 8mm x 30mm Head Cap Screw M8X40 8mm x 40mm Head Cap Screw 8MMWASHERXL 8mm Flat Washer XL ALS 027 Aluminum Spacer RACE SPS 1 Me2. Drain hole must be closer to the rear of the vehicle d Remove the two rear brace bolts and install supplied heatshield on top of rear support brace using the stock bolts as shown in Fig 6 Check to make sure the two heatshield holes align to the rear bed mounting holes Torque brace bolts to factory specification e Install rubber grommets and spacers onto muffler bracket f Install rubber grommets and spacers onto tailpipe bracket Stock Heatshield 2 Installing the header a Install Yoshimura header using stock bolts Inspect stock exhaust manifold gasket and replace if necessary P N 5811511 Do not torque header bolts at this time 5420 Daniels Street Chino CA 91710 Tel 800 634 9166 Fax 909 591 2198 www yoshimura rd com 394000G551_1 doc Page 2 of 4 a a b c 3 Installing the muffler tailpipe assembly Install midpipe to header Install stock exhaust ring gasket to tailpipe Install muffler and tailpipe assembly from the rear Connect midpipe to tailpipe and install springs Install midpipe to header springs Torque header bolts to 16 5 Ib ft 23 Nm Torque tailpipe bolt to 9 5 Ib ft 13 Nm Torque muffler bolts to 9 5 Ib ft 13 Nm 4 Reinstall bed assembly and fenders Re install bed assembly and fenders as per FSM 5 Fitment check and Notes Before starting vehicle check for proper clearance between new exhaust system and rear suspension i e tire
3. control 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 It is 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 NOTE After starting vehicle 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 394000G551_1 doc Page 3 of 4 Spark Arrester Cleaning Information SOSIIIMURA Read through all instructions before beginning installation Exhaust system can be extremely hot Let vehicle cool down before beginning installation Always wear hand and eye protection and take precautionary measures to avoid injury Part Description Qty EE M6X18BHS 6mm x 18mm Button Head Cap Screw a ee ee ee soo eo a tors 2 rr ae ee ee TOOLS REQUIRED 4mm Allen Key Wire Brush Pair of Gloves Safety Glasses Cleaning Steps 1 Using a 4mm Allen key remove the 6mm x 18mm Button Head Bolt located under the muffler exhaust tip See Parts Diagram for location 2 Remove the spark arrester from the muffler 3 Using a wire brush remove carbon deposits from spark arr
4. dium Spring RACE SPX 1 Short Spring ST 200 Spring Puller Tool 347PLUG End Cap Plug 17029 Yoshimura Sticker Sheet 39400 HS Aluminum Heatshield Optional Replacement Parts SA 01 K Replacement SA Kit REPACK RS8T P22 Re pack Kit 5420 Daniels Street Chino CA 91710 Tel 800 634 9166 Fax 909 591 2198 www yoshimura rd com 394000G551_1 doc HEH ee Here x No a 8 E 2 aS 1 a Page 1 of 4 TOOLS REQUIRED Metric Socket Set Combination Wrench Set Torque Wrench Metric Allen Wrench Set Power Drill and 5 16 Drill Bit REMOVAL 1 Removing the stock exhaust system a Remove rear fenders and bed assembly as per Factory Service Manual FSM b Remove the stock heat shield c Remove the 2 springs attached to the header and tailpipe d Remove the 4 header bolts and remove header e Loosen exhaust clamp and remove stock tailpipe f Remove stock muffler and stock muffler grommet in frame See Fig 1 INSTALLATION 1 Small parts installation a Install provided spacer and muffler hanger bracket on frame See Fig 2 3 and Parts Diagram for orientation b Using a drill and a 5 16 drill bit drill out the 2 holes near the middle of the heat shield c Place tailpipe hanger bracket on crossbeam aligning the mounting holes Then place the stock heat shield over the tailpipe hanger bracket and bolt down using supplied hardware See Fig 4 5 Note
5. ester screen Inspect the screen for excessive wear or damage If spark arrester is excessively worn or damaged the spark arrester must be replaced Cleaning and inspection should be performed at the same time as muffler re packing Re packing is recommended every 1 000 miles CAUTION Gloves and safety glasses should be worn while cleaning spark arrester 4 Re install spark arrester and 6mm x 10mm bolt into muffler assembly Torque bolt to 1 0 kg m 7 3 lb ft NOTE It is highly recommended that a low strength Loc tite is used on the bolt 5420 Daniels Street Chino CA 91710 Tel 800 634 9166 Fax 909 591 2198 www yoshimura rd com 394000G551_1 doc Page 4 of 4
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