Installation Instructions & Parts Diagram
Contents
1. e disconnected wire N Reinstall orange cap onto grey wiring harness plug and reconnect plug to ECU 8 Reinstall the metal brace and rider seat Fig 5 Part List 111627 3 6 8 S Stock NO DESCRIPTION QTY PART 1 Yoshimura Race Slip On Tailpipe 1116 437 2 TRC Tri Oval Muffler Assembly PA ae Carbon Fiber Sleeve uses CTS081 6 Exhaust Collector Clamp 1 22059 i Yoshimura Vinyl Sticker 17028 BLK 3 TRC Stainless Steel Muffler Clamp 1 Stainless Steel or Titanium Sleeve uses CTS081X Parts Diagram Nuts and Bolts Guide Actual Size 8mm Large Flat Washer 8mm Flange Nut SUZUKI AMERICAN SUZUKI MOTOR CORPORATION MOTORCYCLE January 21 2009 VOLUNTARY SAFETY RECALL CAMPAIGN 2A08 2005 AND 2006 GSX R1000 MOTORCYCLES FRAME REINFORCEMENT BRACE INSTALLATION FRAME REPLACEMENT PLEASE READ IMMEDIATELY Dear Suzuki Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Suzuki Motor Corporation has decided that an issue related to motor vehicle safety may arise with respect to some model year 2005 and 2006 GSX R1000 motorcycles According to our records you are the owner of one of these motorcycles Why is Suzuki conducting this recall Suzuki has received reports of cracking or breakage of the motorcycle frame in certain extreme situations where unusually high stress is placed on the frame such as col2. e to be left at the dealership overnight so that the epoxy adhesive that is used can cure The service will be performed at no cost to you for parts or labor Should cracks be found during the inspection the frame will be replaced with a new frame that has the reinforcement brace installed see exclusions at the bottom of this page To reassure your confidence in your Suzuki GSX R1000 Suzuki will provide a five year warranty on your frame and the frame reinforcement brace beginning on the date of installation by your dealer How do I receive the fastest possible service Suzuki understands that your riding time is precious Our suggestion is to work closely with your authorized Suzuki dealer to get the Recall service scheduled as quickly as possible When you pick up your serviced motorcycle please allow a few extra minutes for your dealer to prepare and complete the necessary paperwork with you If you have special circumstances discuss them with your Suzuki dealer Suzuki understands that some customers may have difficult circumstances to overcome in bringing their motorcycle to the dealership for the Recall service We have asked your Suzuki dealer to work closely and flexibly with you to arrange solutions for your special reguests Please remember however that each dealership has its own limitations in providing special assistance due to dealership location available time and staff size Your dealer can also consult with Suzuki regard
3. ing other alternatives What motorcycles are excluded from this Recall Any motorcycle with a frame modified in such a manner that the reinforcement brace could not be installed is excluded from this Recall This Recall is being undertaken voluntarily and not pursuant to the vehicle warranty The acceptance or exclusion of any vehicle for the service and installation described above shall not be construed as modifying or waiving the terms of the vehicle warranty in any respect Questions and Answers Your Suzuki dealer has been provided with specific and complete instructions regarding the Recall service Your local Suzuki dealer can provide the fastest responses to your questions or concerns about the Recall service You may also contact the American Suzuki Customer Service Department for assistance at 714 572 1490 You will need to have your Vehicle Identification Number ready when calling If you believe that American Suzuki has failed to provide the Recall service without charge or is unable to do so within a reasonable time you may submit a complaint to the Administrator of the National Highway Traffic Safety Administration 1200 New Jersey Ave S E Washington DC 20590 or call the toll free Vehicle Safety Hotline at 1 888 327 4236 TTY 1 888 424 9153 or go to http www safercar gov Locating an Alternate Dealer Suzuki dealers can be located on the internet at www suzukicycles com or by calling the Customer Service number listed abo
4. lisions involving the front wheel fork assembly Suzuki has also received reports of cracking or breakage of the frame behind and below the steering neck when the motorcycle is subjected to repeated hard landings from hazardous maneuvers such as extreme or extended wheelies or other stunts Suzuki believes that this type of driving activity is reckless and illegal when performed on a public roadway and does not condone it If the frame becomes broken during this type of extreme use a crash could occur While ordinary operation of the motorcycle does not create a risk of cracking or breakage of the frame Suzuki has decided voluntarily to conduct this Safety Recall to minimize the potential for frame cracking or breakage in the circumstances described above What will Suzuki do Your Suzuki dealer will inspect the relevant area of the frame for cracks The illustration on page 2 shows the area to be examined for cracks lf no cracks are found a frame reinforcement brace will be attached to the frame using bolts and epoxy adhesive The brace is aluminum and very lightweight less than 2 pounds It is very slender and fits underneath the top spar of the frame behind and below the steering neck The appearance performance and handling of your Suzuki remain unchanged with the reinforcement brace installed The service to inspect your frame and install the reinforcing brace takes approximately 3 hours to complete and your motorcycle will hav
5. ment PO Box 1100 Brea CA 92822 1100 or call 714 527 1490 Be sure to have your VIN information available when calling We thank you for your prompt attention to having this Safety Recall service performed on your GSX R1000 and apologize for any inconvenience it may cause you We would also like to remind you that you can avoid future problems through legal and safe operation of your motorcycle at all times Your safety satisfaction and riding enjoyment are priorities for Suzuki Sincerely American Suzuki Motor Corporation
6. nt and frame chassis mount Loosen stock collector clamp and remove stock muffler assembly from collector outlet See Fig 2 4 Remove both passenger foot rests 5 Install Yoshimura high exit muffler bracket using stock bolts 6 Slip supplied collector clamp over inlet of Yoshimura tail pipe then slip tail pipe inlet over stock collector outlet 7 Line up chassis mount on Yoshimura tailpipe with stock chassis mount location Mount tail pipe to inside of chassis mount using stock bolt and washer and supplied nut and washer See Fig 3 Fig 2 8 Torque chasis mount bolt to 2 5 kg m 16 Ib ft 9 Apply heat insulator to inside of muffler clamp and slide clamp onto muffler note direction of clamp in Fig 4 10 Mount clamp to outside of Yoshimura muffler bracket using stock bolt washer and nut see Fig 3 and 4 11 Torque muffler clamp bolt to 2 3 kg m 16 Ib ft 12 Torque supplied collector clamp to 1 25 kg m 9 Ib ft 13 Reinstall right side falring Installation Procedures Page 3 14 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 Aluminum Clamp Bracket 8mm Xx 25mm Hex Bolt 15 Check for proper clearance between new exhaust LJ Stainless Steel i system and motorcycle i e Swing arm body work il TTT R etc If any problem is found
7. please carefully follow i o through the installation steps again If problem still a persists please call Yoshimura tech dept at s 800 634 9166 in CA 909 628 4722 Insulator Note After starting motorcycle it is normal for new Fig 4 exhaust system and muffler to smoke until oil residue burns off Installation Procedures Page 4 Necessary Wiring Changes 1 It is 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 2 Remove rider seat and metal brace located over the ECU by removing the four bolts See Fig 1 3 With ignition in OFF position disconnect the grey wire harness plug from the ECU See Fig 2 Fig 1 4 Remove the orange cap on the grey wire harness plug a by pressing the small orange tabs apart and pulling the orange cap off See Fig 3 Fig 3 Installation Procedures Page 5 5 Pull out the black wire with brown stripe See Fig 4 When you hold the grey plug with the locking tab facing up the black wire with brown stripe is in the top row In the 8th slot from the left See Fig 5 Insert a very small flat head screwdriver into the hole that the arrow is pointing to in Fig 5 Gently pry up with the screwdriver to unlock the wire and pull on the black wire with brown stripe from the rear of the plug to remove O Tape and secur
8. sOSHIMURA RESEARCH amp DEVELOPMENT OF AMERICA INC 5420 DANIELS STREET STE A CHINO CA 91710 800 634 9166 909 628 4722 FACSIMILE 909 591 2198 www yoshimura rd com TRE TRI OVAL PERFORMANCE EXHAUST SYSTEM SUZUKI 2005 2006 1116276 TRC HIGH EXIT SLIP ON SYSTEM WITH STAINLESS STEEL SLEEVE GSX R1000 1116278 TRC HIGH EXIT SLIP ON SYSTEM WITH TITANIUM SLEEVE TRC HIGH EXIT SLIP ON SYSTEM WITH CARBON FIBER SLEEVE i i i Voshimura R amp D of A erica Voshimura R amp D yd Americe i i i i i ION GSX cu i Slip on vs Stock a par dite Sesto cn ati THIS PRODUCT IS DESIGNED FOR USE IN CLOSED COURSE RACING AND IS NOT INTENDED FOR HIGHWAY USE NOTE IN THE STATE OF CALIFORNIA IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM WHICH INCLUDES THE FUEL INJECTION OF ANY VEHICLE Installation Procedures Page 2 Caution Exhaust system can be extremely hot Let motorcycle cool down before beginning installation Note Read through all instructions before beginning installation Tools Needed 11 and 12mm socket 3 9 ratchet and extension OSHIMURA 12mm wrench 4mm and 6mm allen wrench Torque wrench Installation Steps 1 Remove right side fairing See Fig 1 2 Disconnect tail pipe exhaust valve cables from EXCVA servo located next to the rear shock Refer to owner s service manual for removal instructions 3 Unbolt stock muffler and tail pipe from passenger foot rest mou
9. ve Customer Reimbursement If your motorcycle is included in the Safety Recall and you have paid for the repair or replacement of the frame due to cracking or breakage of the frame in the relevant area you may be eligible for full or partial reimbursement Suzuki s reimbursement plan covers the following motorcycles all 2005 and 2006 model year Suzuki GSX R 1000 motorcycles Please note the following for which Suzuki may exclude reimbursement e The cost of repairs to correct damage resulting from crashes accidents or other similar incidents will not be reimbursed e Only repairs that are the subject of the Safety Recall are reimbursable Additional expenses such as towing rental accommodations property damage repairs etc will not be reimbursed Reimbursement may be limited to suggested list price on parts and the Suzuki published flat rate time allowance e An owner will not be eligible for reimbursement if the expenses for repairs are incurred more than 10 days after the date of the last owner notification letter sent by Suzuki e Reimbursement claims may also be excluded when adequate documentation Is not submitted by the claimant Your authorized Suzuki dealer will reguest an original or copy of your receipts for the repair or replacement work done and your owner notification letter To obtain information or reguest reimbursement contact your Suzuki dealer or the American Suzuki Motor Corporation Motorcycle Customer Service Depart
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