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CAUTION: 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.
WARNING: Always properly support vehicle with
a stand and/or lift when servicing or
performing any work. Unstable
vehicles may present dangerous
conditions and may cause property
damage and/or personal injury.
NOTE:
Read through all instructions before
beginning installation.
Removal
1. Remove the right side panel.
2. Loosen muffler exhaust clamp.
3. Remove muffler tailpipe chassis mount bolt.
4. While securely supporting the stock muffler
assembly, remove muffler mount bolt and
carefully remove the stock muffler assembly.
5. Remove the header nuts and carefully remove
the stock header.
1
Note : The stock exhaust port gasket will be re-
used with the Yoshimura full-system
exhaust. Inspect and replace if
necessary.
2
Note : If having difficulty removing the stock
header, inspect stock header flange
and/or exhaust port studs to see if bent.
It may be necessary to use a soft mallet
to remove the stock header off of the
studs. After removing stock header,
inspect exhaust port stud threads for
damage and check to see if bent.
3
Note : If exhaust port studs are bent, the
Yoshimura header flange may not fit and
the bent studs must be removed from the
cylinder head prior to installing the
Yoshimura system. It is recommended to
replace using OEM studs. See
supplemental exhaust port stud removal
instructions at the end of this manual if
necessary.
Installation
1. Install 22585-106, Yoshimura header using the
stock header nuts. Do not torque at this time.
2. Install Z1024, rubber grommet into muffler
bracket and install ALS-043, aluminum spacers
to the frontside and backside of the grommet.
3. Install 225850S321-RMA, Yoshimura muffler by
sliding onto header outlet. Align tailpipe chassis
mount bracket and muffler mount bracket to
subframe and secure using the stock chassis
mount and muffler mount bolts. Do not torque at
this time.
4. Torque header nuts to factory specification.
Note: If studs were removed and using M8X25H,
8mm bolts, torque to 23 Nm (2.3 kg-m,
17 ft-lb).
5. Torque tailpipe chassis mount bolt to factory
specification.
6. Torque muffler mount bolt to factory
specification.
7. Using the ST-200, spring puller tool provided in
the kit, install RACE-SPX-2, short exhaust
springs between flange and header.
8. Install RACE-SPS-1, medium exhaust spring
between muffler tailpipe and header connection.
9. Re-install right side panel following the
opposite steps of removal.
3
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