1. Remove left and right side fairing.
2. Remove the three bolts that secure the black
muffler protector, exposing the exhaust valves
and exhaust clamp.
3. Disconnect and remove the exhaust valve
cables (refer to your service manual for
complete removal instructions).
Note: Do not unplug servo motor. Unplugging
the servo motor may cause the bike to
run in a power limited fail safe mode.
4. Loosen the stock exhaust clamp
5. While securely supporting the stock muffler,
remove the muffler mount bolt and carefully
remove the stock muffler assembly by sliding
toward the rear of motorcycle.
6. Remove O2 sensor from the stock header.
7. Remove the two header chassis mount bolts.
8. While securely supporting the stock header
assembly, remove header nuts and carefully
remove the stock header assembly.
Note: The stock exhaust port gaskets will not be
used with the Yoshimura full-system.
Remove gaskets from exhaust ports
before installing Yoshimura manifolds.
9. Remove the bolt securing left side muffler stay
to frame as it will not be used with the
Yoshimura full-system.
Removal
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.
1. Install (No. 1)
13630SDM,
manifold and (No. 2)
YZ616SDR-04,
flange onto exhaust port using
the stock header nuts. Do not torque at this time.
See below for proper orientation of flanges.
Note: Hook (No. 7)
RACE-SPS-1,
medium
exhaust springs onto flanges before
installing header. Access will be limited
once header is installed.
2. Install (No. 3)
13630-404/13630-704,
header
onto manifolds by slipping one header leg at a
time from one end to the other. Using a rubber
mallet, gently tap header legs to make sure
header is fully seated onto the manifolds.
Remove Left Side Muffler Stay
Installation
2
1
Flange Orientation & Spring Location
Incorrectly Seated
Correctly Seated
