this product is designed for use in closed course racing

RESEARCH&DEVELOPMENT OF AMERICA, INC.
5420 DANIELS STREET STE A, CHINO CA., 91710 · (800)634-9166 · (909)628-4722 · FACSIMILE (909)591-2198
www.yoshimura-rd.com
RS -3 OVAL PERFORMANCE EXHAUST SYSTEM
SUZUKI
2003-2007 113 0 0 5 (2 ,5 ,7)
SV1000S
S TA INLE S S S TE E L RA CE 3/4 S Y S TE M
85
120
1130055
100
SAE Corrected HP
90
Stock
80
70
60
50
40
30
20
Yoshimura R&D of America
2003 SUZUKI SV1000S
1130055 vs. Stock
10
0
3000
4000
5000
6000
7000
RPM x1000
8000
9000
10000
SAE Corrected Torque (lb-ft)
110
75
1130055
65
Stock
55
45
35
Yoshimura R&D of America
2003 SUZUKI SV1000S
1130055 vs. Stock
25
15
2800
4800
6800
8800
RPM x1000
Note: Dyno graphs are for comparison use only. Actual results may vary depending on operating and motorcycle condition.
!
THIS PRODUCT IS DESIGNED FOR USE IN CLOSED COURSE
RACING AND IS NOT INTENDED FOR HIGHWAY USE.
!
NOTE: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM. WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.
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:
Socket and Wrench Set
Ratchet Wrench and long extension
6mm Allen wrench
Torque wrench
Installation Steps:
1 Remove lower cowling. (See Fig. 1)
2
Loosen exhaust collector clamp where stock front and
rear header connect. Unbolt exhaust flange bolts and
remove stock front header. (See Fig. 1)
3 Remove stock mufflers and stock rear header. Loosen
exhaust clamp on rear stock header tube. Unbolt
header chassis mounts (left and right sides) and
remove header.
Loosen Header Clamp
Fig. 1
Note: Removal of kickstand may help in increasing
clearance during disassembly. Please note to safely
secure the bike on a rear stand.
4 Replace old exhaust port gasket on front cylinder with
new exhaust port gasket. (Not supplied - Suzuki part
no. 14181-31D00)
5 Slip supplied collector clamp over rear exhaust port
tube on Yoshimura header .
6 Install Yoshimura header by slipping rear exhaust port
tube into stock rear header tube. Do not tighten
collector clamp at this time.
Fig. 2
Note: Rear header can be difficult to install. Start
header on the stock rear header tube. Simultaneously
twist and push header until in position. Chassis
mount goes to the inside of stock chassis mount
location. Once chassis mount bolt hole is lined up
header is located properly.
7 Install chassis mount bolt using stock bolt, washer
and nut. (See Fig. 2) Do not tighten at this point.
Rear Collector Clamp
Note: For 2004-2007 models, install supplied bolt,
washer, and aluminum spacer as shown in Fig 5.
Fig. 3
Installation Procedures:
8 Re-install stock front header using stock bolts
and supplied collector clamp. If stock collector
gasket sticks to stock header it must be removed.
Torque header bolts to 2.0 kg-m (14.5 lb-ft).
Page 3
Stock Nut
Chassis
Mounting
Bracket
Stock Chassis
Mount Bolt with
washer
9 Torque front and rear collector clamps to 1.25 kgm (9 lb-ft).
10 Install Yoshimura muffler. (Adjust muffler by
twisting it until it’s vertically aligned and not
canted to one side or the other)
11 Install supplied exhaust springs between tailpipe
and muffler.
Header Mounting
Bracket
Fig. 4
12 Install heat insulator to inside of muffler clamp
and slide clamp onto muffler. (Note direction of
clamp in Fig. 6)
13 Mount muffler clamp to inside of stock muffler
bracket using stock bolt, washers and nut.
(See Fig. 6) Torque bolt to 2.5 kg-m (18 lb-ft).
Chassis
Mounting
Stock Nut
ALS-014
Bracket
M8X50H
NOTE: Adjustment of the Yoshimura Header may be
necessary. Ensure that the rear shock lower
linkage has sufficient clearance.
8mm Washer
14 Torque chassis mount bolt to 2.5 kg-m (18 lb-ft).
Header Mounting
Bracket
15 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.
16 Check for proper clearance between new exhaust
system and motorcycle. (i.e. radiator, oil pan,
swing-arm, 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
NOTE: After starting motorcycle, it is normal for new
exhaust system and muffler to smoke until oil
residue burns off.
Fig. 5
Stock Muffler
Bracket
Stock Bolt
and Washer
Stainless Steel
Clamp
Stock Nut
and Washer
Heat
Insulator
Fig. 6
Part List:
Page 4
#113005(2,5,7)
Parts Diagram
NO.
DESCRIPTION
1 Yoshimura Header Collector
Stainless Steel Race
2 RS-3 Oval Muffler Assembly
3 Stainless Steel Muffler Clamp
Stainless Steel or Titanium Sleeve uses
Carbon Fiber Sleeve uses
4 Header & Collector Clamp
5 8mm Flange Nut
6 2.5" Race Springs
7 Yoshimura Race Tailpipe
8 Stainless Steel Clamp
9 Aluminum Insert Spacer
10 8mm Flat Washer
11 8mm x 50mm Flange Bolt
** Muffler Clamp Heat Insulator
** Spring Puller Tool
** Yoshimura Vinyl Sticker
QTY
1
1
1
2
1
2
1
1
1
1
1
1
1
1
PART #
Nuts and Bolts Guide (Actual Size):
1131-410
**
COS450S8BSX
COS450S8BS
220-59
8MMNUT
RACE-SPS
1131-419
20067
ALS-014
8MMWASHERL
M8X50H
HT SHLDTRS
ST-200
17029
8mm Flange Nut
8mm Large Flat Washer
8mm x 50mm
Flange Hex Bolt