GSXR(02) "UTSX" Instruction.qxd (Page 2)

HOTBODIESRACING.COM
GSX-R600/750 EXHAUST KIT
(Undertail Exhaust Kits Available in: Black, White, Silver, Yellow, telephonica Blue or Alstare Purple)
CAREFULLY READ ALL INSTRUCTIONS BEFORE BEGINNING THE
INSTALLATION PROCESS! AS WITH ANY PERFORMANCE MODIFICATION,
YOU SHOULD ALWAYS CHECK YOUR WARRANTY BEFORE MAKING ANY
MODIFICATIONS TO THE EXHAUST CANISTER OR EMISSIONS DEVICES.
HOTBODIES RACING WILL NOT BE HELD RESPONSIBLE FOR ANY MISUSE OR DAMAGES
CAUSED BY THE INSTALLATION OF THIS PRODUCT, NOR WILL WE REPLACE ANY STOCK
PARTS TO YOUR MOTORCYCLE.
HOTBODIES RACING RECOMMENDS THAT YOU HAVE A PROFESSIONAL MECHANIC
PERFORM THIS INSTALLATION, THIS PRODUCT WILL REQUIRE RE-MAPPING OF THE
FUEL INJECTION TO GET ITS FULL POTENTIAL, WE SUGGEST USING A “POWER
COMMANDER III” AND HAVING IT PROFESSIONALLY TUNED USING A DYNOMETER
AND AN EXHAUST GAS ANALYZER.
IF YOU CHOOSE TO “DO-IT-YOURSELF”, WHICH WE DON’T RECOMMEND, ALWAYS
TAKE APPROPRIATE SAFETY MEASURES WHEN INSTALLING THIS PRODUCT, SUCH AS
SAFETY GOGGLES AND LEATHER GLOVES.
Your Undertail Exhaust kit should include the following parts:
1 – Exhaust canister
1 – Large Hose Clamp
1 – Mid Pipe (S-Bend)
1 – Exhaust brackets (U & L shaped)
1 – Battery Box
2 – Skinny Spacers (Gold Color)
2 – Wider Spacers (Silver Color)
1 – Undertail w/ heat shielding
1
2
2
2
–
–
–
–
small 10mm head bolts
Longer Heel Guard Bolts
Longer Foot peg bolts
Phillips head bolts
1) Removing The Stock Parts Before the Installation of Undertail Exhaust Kit
a) Carefully remove the right side bodywork panel and inner fairing panels. Save all bolts, washers and plastic
rivets for re-installation of these parts.
b) Remove drivers seat and Passenger seat or seat cowl. Remove tail section and brake light. Save all bolts,
washers and plastic rivets for re-installation of these parts.
c) Remove Mud flap and stock glove box assembly, leave all electrical components hanging on left side of sub
frame. All washers and bolts will NOT be needed for the installation of our product, save for a rainy day.
d) Remove exhaust hanger bolt (bottom of right side passenger peg) and now you can remove the stock canister
from the headers.
e) Remove right side foot peg.
f) Now is a good time to remove the passenger pegs if you won’t be using them again. They can be used with the
system.
Read carefully before installation: This exhaust like all after market exhaust has been designed for racing use only. Hot Bodies Racing,
our distributors, or our dealers will NOT be responsible for any misuse or improper use or installation of this product. This product has NOT been
presented for D.O.T. certification, always check with your local Department of Motor Vehicles before modifying any aspect of your motorcycle.
2)
Measure 1.25” from the the weld near where the
exhaust mounting point is located on the right side of
the motorcycle, mark with tap so you have a straight
line.
3)
CAREFULLY cut header pipe to allow the new mid pipe
to mount to bike. We used a hack saw with the blade
reversed to cut away from the bike.
4)
Replace right side foot peg using the 2 silver spacers
and the 2 longer mounting bolts. Also space out the
heal guard using the 2 gold colored spacers and longer
mounting bolts.
5)
loosen (DO NOT REMOVE) right side exhaust mounting
point of the header as shown.
6)
Slide pipe over cut header and attach at the stock
mounting position for the battery box using stock bolt.
Re tighten right side exhaust mounting point from step
#5.
7)
Attach exhaust clamp on to header as shown, make sure
its tight.
8)
Attach “U” and “L” brackets in between tail cowl latch
using the larger bolt and lock nut.
9)
Attach canister to mid pipe using the #238 Clamp as
shown.
10)
Slide large clamp over the canister as shown, careful
not to scratch the canister. Place hose clamp the “J”
bracket and tighten.
11)
Place new battery box into position. The box will be
snug, make sure the top is flush with the subframe.
12)
position the negative lead through the hole on the
backside of the box.
13)
Using a zip tie, fasten the tip-over switch to the front
side of the battery box. make sure the “Upper w/ the
arrow” is facing up, or the bike will not start.
14)
Place the battery in the box as shown, connect the
positive and negative leads to battery, make sure
cover is over the positive lead.
15)
Place Heat shield on the flat side of the ECU.
16)
Place the ECU in the battery box as shown, connect to
the harness.
17)
Electronics should be firmly zip tied to the sub frame
and away from the exhaust using the stock zip ties.
18)
While the tail is off the bike. Attach the undertail to the
tail section at the end and mark the 2 lower mounting
points. Drill holes in tail, not any larger than necessary.
Check fit undertail, adjust if necessary.
19)
Install seat lock into the undertail.
20)
place stock tail section on the bike. Cover rear tire and
rest undertail on the rear tire while wiring the tail and
signal lights. Use the color codes below to attach the
LEDs.
New Wire Color
Stock Wire Color
Brake:
White/black tracer
Red
Running:
Brown
Blue
Ground:
Black/white tracer
Black
Lft. turn:
Black w/ gold marks
Orange
Rt. Turn:
Aqua w/ gold marks
Orange
21)
23)
Mount License plate bracket sweeping backward to
under tail 1-1.5” behind opening for the exhaust, or in
desired location.
If your tail is drooping behind the seat cowl, fix using 2
zip tied and bolts provided.
22)
Mount undertail to tail section using plastic screw
rivets. Make sure all wiring from light is clear of
exhaust canister. Adjust canister if necessary to
center of the hole.
YOUR DONE! JUST REMEMBER!!!
If you have any questions about the part(s) or need further help with the installation call us at 800-555-2805
or email us at [email protected]. This installation does require a professional mechanical aptitude, if in doubt
have a professional mechanic perform the installation, 3 hours is the average installation time with dyno tuning.
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