Installation Procedures:
Page 3
8mm x 65mm
Flange Hex Bolt
Heat
Insulator
Stainless Steel
Muffler Clamp
Aluminum
Spacer
Stock Chassis Mounting
Point
Large Washer
Fig. 3
Connect Springs
Heat Shield
7 Insert supplied aluminum spacer into the inside of the
rubber grommet. See parts diagram on page 4 for
orientation.
8 Install Yoshimura tailpipe with muffler onto Yoshimura
header. Install supplied springs onto header-tailpipe
with supplied spring puller tool. (See Fig. 4)
9 Mount muffler to upper chassis mount. Mounting
orientation should go as follows: Supplied bolt,
washer, muffler mounting bracket w/ inserted rubber
grommet, aluminum spacer, aluminum spacer, frame
(See Fig. 5 and Parts Diagram).
10 Torque stock header nuts to to 2.0 kg-m (14.6 lb-ft)
11 Torque muffler mounting bolt to 2.5 kg-m (18 lb-ft).
12 Reinstall radiator hose and clamp.
13
14 Fill radiator with new coolant.
15 Refer to factory service manual for steps on bleeding
the cooling system.
16 Reinstall radiator cap.
17 It is recommended that the entire exhaust system 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.
18 Before starting motorcycle check for proper clearance
between new exhaust system and motorcycle. (i.e.
radiator & fan assembly, rear brake, frame, tire, 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
THERMOSTAT COVER INSTALLATION
• Install the thermostat in the reverse order of
removal.
• Apply engine coolant to the rubber seal on the
thermostat.
• After installing the thermostat, be sure to add
engine coolant.
Note: After starting motorcycle, it is normal for
new exhaust system and muffler to smoke
until oil residue burns off.
Fig. 4
Fig. 5
Summary of Contents for 03-09 SUZUKI LT-Z400
Page 6: ......
