RESEARCH&DEVELOPMENT OF AMERICA, INC.

www.yoshimura-rd.com

YOSHIMURA PERFORMANCE EXHAUST SYSTEM

SUZUKI2006-2012

DR-Z 400S/M2166523

DUAL ALUMINUM SLEEVE STAINLESS STEEL

RS4 FULL SYSTEM

5420 DANIELS STREET STE A, CHINO CA., 91710 · (800)634-9166 · (909)628-4722 · FACSIMILE (909)591-2198

NOTE: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM, WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.

THIS PRODUCT IS DESIGNED FOR USE IN CLOSED COURSE RACING AND IS NOT INTENDED FOR ANY OTHER USE.! !

Installation Procedures: Page 2

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.

Note: Read through all instructions before beginning installation.

Installation Steps:

Tools Needed:Metric socket set3/8” ratchet and extensionAllen bit set for torque wrenchTorque wrench

1. Remove stock exhaust system.

2. Remove stock muffler mounting bracket/passenger foot pegs.

3. Support bike using jack stands or a rearstand.

4. Remove stock kickstand.

5. Remove kickstand sensor bolts. (Fig. 3)

6. Apply blue loctite to supplied bolts and install Yoshimura kickstand bracket and kickstand sensor to the stock mounting location. Torque to 12 lb-ft (16.2 N-m)

7. Install Yoshimura kickstand using stock bolt and nut. Torque to 18 lb-ft (24.3 N-m)(Note: Supplied Delrin Washer may be used to achieve a snug fit if needed)

8. With bike secured, install stock kickstand springs using supplied spring puller tool. (Caution: Wear safety glasses and use extreme caution while pulling as stock springs have a high spring tension.)

9. Once kickstand is installed, take bike off of jackstands or rearstand.

10. Install new gasket and install Yoshimura header using stock nuts. Do not torque at this time.

11. Install Yoshimura muffler hanger brackets using supplied hardware. Torque to 14 lb-ft (18.9 N-m)

12. Install rubber grommets into the Yoshimura muffler brackets. Install the thin spacer into the inside of the left muffler rubber grommet. Install the thick spacer into the inside of the right muffler mount rubber grommet. (See parts diagram for orientation.)

Fig. 2

Fig. 1

Fig. 3

Delrin Washer

Remove Stock Muffler

Install Yoshimura System

Installation Procedures: Page 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.

Note: Read through all instructions before beginning installation.

Installation Steps:

Fig. 5

Fig. 4

13. Install right muffler assembly into the header collector. Bolt to muffler hanger bracket using supplied bolt, washer and nut. (See parts diagram for orientation.) Do not torque at this time.

14. Repeat for left muffler assembly.

15. Install supplied exhaust springs.

16. Check all critical clearances. Adjust header or tailpipes as necessary. (Note: CAREFULLY, as not to hit the muffler sleeve, raise kickstand and check that there is sufficient clearance between the muffler sleeve and kickstand bottom plate.)

17. Once desired fitment is achieved torque header nuts to 14 lb-ft (18.9 N-m).

18. Torque right and left muffler mounting bolts to 18 lb-ft (24.3 Nm).

19. 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.

20. Before starting motorcycle check for proper clearance between new exhaust system and rear suspension (i.e. rear brake, frame, shock spring, etc). If any problem is found, please carefully follow through the installation steps again. If problem still persists, please call Yoshimura technical department at (800)634-9166 / in CA (909) 628-4722 .

Note: After starting motorcycle, it is normal for new exhaust system to smoke until oil residue burns off.

Large Spacer

Check Clearance With Swingarm

Check Kickstand to Muffler Clearance

Kickstand Plug Installation:

1. Remove seat.2. Remove wire harness cover. (Fig. 1 )3. Unplug green kickstand sensor plug.4. Install Yoshimura kickstand bypass plug. (Fig. 2)5. Reinstall wire harness cover and seat.

Installation Procedures: Page 4

Cutting Template Placement

Supplied Shim

Fig. 1

Fig. 2

Fig. 1 Fig. 2

Green Plug

Remove

Closed Course Competition Air Box Modification:

1. Remove seat.2. Cut supplied 3.625” x 4.5” template.3. Place template onto airbox as shown in Fig. 2 Mark outline of template with a permanent marker.4. Remove airbox and filter.5. Cut airbox along the drawn outline.

Note: Be sure to clean airbox of any debris before reinstalling onto motorcycle.

Closed Course CompetitionJetting Recommendations: Stock Main JetMikuni Pilot Jet# 25Install supplied shim onto needle. See Fig 1

WARNINGIN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM. WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.

Installation Procedures: Page 5

DR-Z 400 S/M AIRBOX CUTTING TEMPLATE

Front

Part List: Page 6

2166523

Parts Diagram

S

1

2

317

16 15

7

14 13

1212

11

1110

10

9

8

8

6

5

4

NO. DESCRIPTION QTY PART #

1 Yoshimura Header 1 2166-102

2 Yoshimura Left Muffler Assembly 1 2166523-LMA

3 Yoshimura Right Muffler Assembly 1 2166523-RMA

4 8mm X 30mm Socket Head Cap Screw 1 M8X30

5 8mm X 35mm Socket Head Cap Screw 1 M8X35

6 8mm X 20mm Socket Head Cap Screw 4 M8X20

7 6mm X 12mm Socket Head Cap Screw 2 M6X12

8 8mm Flange Nut 6 8MMNUT

9 Small Race Spring 2 RACE-SPX-1

10 Rubber Grommet 2 Z1021

11 8mm Washer Large 2 8MMWASHERL

12 Aluminum Spacer (Large) 2 ALS-002

13 Left Hand Muffler Bracket 1 2166-BKT-L

14 Right Hand Muffler Bracket 1 2166-BKT-R

15 Yoshimura Kickstand Bracket 1 2166-KST-BKT

16 Yoshimura Kickstand 1 2166-KST

17 Derilin Washer (As needed for kickstand) 1 DWASHER

** Offroad Endcap Plug 2 347PLUG

** Spring Puller Tool 1 ST-200

** Kick Stand Jumper Plug 1 2166-PLUG

** 3mm Washer 1 3MMWASHER

** Yoshimura Vinyl Sticker 1 17029

Parts Diagram

NO. DESCRIPTION QTY PART #

1 6mm X 12mm Button Head Cap Screw 1 M6X12BHS

2 RS4 Spark Arrestor Ring 1.500" 1 RS4-RING-1500

3 TEC-SD10 Spark Arrestor 1 TEC-SD10

4 Yoshimura Exhaust ** **

RESEARCH&DEVELOPMENT OF AMERICA, INC.5420 DANIELS STREET SUITE A, CHINO, CA 91710 · (800)634-9166 · (909)628-4722 · FACSIMILE (909)591-2198

www.yoshimura-rd.com

SA-04-K YOSHIMURA TEC-SD10 SPARK ARRESTOR KIT

1 Using a 4mm Allen key, remove the bolt that secures the aluminum ring and spark arrester to the muffler (see Parts Diagram for location).

2 Remove the spark arrester from the muffler.

3 Using a wire brush, remove carbon deposits from spark arrester screen. Inspect the screen for excessive wear or damage. If spark arrester is excessively worn or damaged, the spark arrester must be replaced. Cleaning and inspection should be performed after every 60 hours of use.

CAUTION: Gloves and safety glasses should be worn while cleaning spark arrester.

4 Re-install spark arrester and aluminum ring. Torque the spark arrester securing bolt to 1.0 kg-m (7.3 lb-ft). NOTE: It is recommended that a low strength “Loc-tite” is used on the spark arrester securing bolt.

12

3

4