Suzuki GSX-R1000 K5 05 Yoshimura Tri-Oval Performance Exhaust Manual ENG.pdf

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111626(2,5,7)
RESEARCH&DEVELOPMENT OF AMERICA, INC.
5420 DANIELS STREET STE A, CHINO CA., 91786 · (800)634-9166 · (909)628-4722 · FACSIMILE (909)591-2198
www.yoshimura-rd.com
TRS TRI-OVAL PERFORMANCE EXHAUST
SUZUKI
2005
GSX-R1000
Slip-On
Slip-On
Stock
Stock
Yoshimura R&D of America
2005 Suzuki GSX-R1000
Slip-On vs Stock
Yoshimura R&D of America
2005 Suzuki GSX-R1000
Slip-On vs Stock
Note: Dyno graphs are for comparison use only. Actual results may vary depending on operating and motorcycle condition.
NOTE: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM. WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.
1116262 TRS RACE SLIP-ON SYSTEM WITH CARBON FIBER SLEEVE
1116265 TRS RACE SLIP-ON SYSTEM WITH STAINLESS STEEL SLEEVE
1116267 TRS RACE SLIP-ON SYSTEM WITH TITANIUM SLEEVE
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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:
10mm, 11mm, and 12mm socket
3/8” ratchet and extension
12mm wrench
4mm allen wrench
Torque wrench
Small Flat Head Screwdriver
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.)
Fig. 1
3 Unbolt stock muffler and tail-pipe from passenger foot
rest mount and frame chassis mount. Loosen stock
collector clamp and remove stock muffler assembly from
collector outlet. (See Fig.2)
4 Slip supplied collector clamp over inlet of Yoshimura tail-
pipe, then slip tail-pipe inlet over stock collector outlet.
5 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
6 Torque chasis mount bolt to 2.5 kg-m (16 lb-ft).
7 Apply heat insulator to inside of muffler clamp and slide
clamp onto muffler. (note direction of clamp in Fig. 4)
8 Mount clamp to inside of stock muffler bracket using
stock bolt, washer, and nut. (see Fig. 3 and 4)
9 Torque muffler clamp bolt to 2.3 kg-m (16 lb-ft)
10 Torque supplied collector clamp to 1.25 kg-m (9 lb-ft).
11 Reinstall right side fairing.
Fig. 3
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Installation Procedures:
Page 3
12 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.
Stock Muffler
Bracket
13 Check for proper clearance between new exhaust
system and motorcycle. (i.e. Swing-arm, body work,
etc.) If any problem is found, please carefully follow
through the installation steps again. If problem still
persists, please call Yoshimura tech. dept. at
(800)634-9166 / in CA (909)628-4722
Stainless Steel
Clamp
Stock Bolt
and Washer
Stock Nut
and Washer
Heat
Insulator
Note: After starting motorcycle, it is normal for new
exhaust system and muffler to smoke until oil residue
burns off.
Fig. 4
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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).
4 Remove the orange cap on the grey wire harness plug
by pressing the small orange tabs apart and pulling the
orange cap off (See Fig. 3).
Fig. 1
Fig. 2
Fig. 3
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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.
6 Tape and secure disconnected wire.
7 Reinstall orange cap onto grey wiring harness plug and
reconnect plug to ECU.
Fig. 4
8 Reinstall the metal brace and rider seat.
Fig. 5
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