1. Remove the right passenger foot peg bracket
assembly to allow more clearance for muffler
removal. For XT models, remove lower cowling.
2. Remove muffler heatshield.
3. Remove the O2 sensor from the stock muffler
assembly.
4. Loosen front and rear header exhaust clamps.
5. Loosen front header flange bolts to allow for
adjustment when removing the muffler
assembly.
6. Remove forward muffler chassis mount bolt.
7. While securely supporting the stock muffler
assembly, remove muffler mount bolt and
carefully remove the stock muffler assembly off
of front and rear header.
1
Note : The muffler exhaust gasket will not be
re-used with the Yoshimura system.
Remove gasket off of rear header.
2
Note : The short stock rear header will be
re-used with the Yoshimura 3/4 system.
Do not remove.
8. Remove front header flange bolts and remove
stock front header.
Note: The stock exhaust port gaskets will be
re-used with the Yoshimura exhaust
system. Inspect and replace if necessary.
Removal
Installation
1. Install (No. 7)
03019127,
exhaust clamp onto
(No. 2)
11621-415D,
midpipe inlet as shown on
the assembly diagram.
2. Install (No. 1)
11621-401D,
front header into
(No. 2)
11621-415D,
midpipe.
3. Carefully align and install (No. 1)
11621-401D
,
header into front exhaust port and (No. 2)
11621-415D,
midpipe onto stock rear header
simultaneously and align midpipe chassis mount
bolt to the backside of chassis mount. Secure
using the stock chassis mount bolt, washer, and
supplied (No. 9)
8MMNUT,
8mm flange nut.
Do not torque at this time.
4. Install (No. 3)
11621-419D,
tailpipe inlet onto
(No. 2)
11621-415D,
midpipe outlet.
5. Install (No. 6)
HT SHLDR77,
muffler clamp heat
insulator onto (No. 5)
1121-MPCRX,
muffler
clamp and trim the excess heat insulator.
6. Install (No. 4)
11621C0520-RMA,
muffler
assembly onto (No. 3)
11621-419D,
tailpipe
outlet.
7. Slide (No. 5)
1121-MPCRX,
muffler clamp over
(No. 4)
11621C0520-RMA,
muffler and align to
frontside of stock muffler mount. Secure using
the stock muffler mount bolt, washer, and nut.
Torque muffler mount bolt to factory specification.
Note: It may be necessary to rotate the tailpipe
and/or the muffler independently until
proper alignment is achieved.
3
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.
6
5
Stock Muffler Mount
s
s
s
5
