this product is designed for use in closed course racing

RESEARCH&DEVELOPMENT OF AMERICA, INC.
5420 DANIELS STREET STE A, CHINO CA., 91786 · (800)634-9166 · (909)628-4722 · FACSIMILE (909)591-2198
www.yoshimura-rd.com
TRS OFFROAD PERFORMANCE EXHAUST SYSTEM
03-09 SUZUKI LT-Z400
03-05 KAWASAKI KFX400
2175152-SA
2175157-SA
TITANIUM PRO FULL SYSTEM WITH CARBON FIBER
TITANIUM PRO FULL SYSTEM WITH TITANIUM
30
2175157
SAE Corrected HP
30
Stock
25
20
15
10
Yoshimura R&D of America
2002 SUZUKI LTZ-400
2175157 vs. Stock
5
0
2500
3500
4500
5500
6500
7500
RPM x1000
8500
9500
10500
SAE Corrected Torque (lb-ft)
35
2175157
25
Stock
20
15
10
Yoshimura R&D of America
2002 SUZUKI LTZ-400
2175157 vs. Stock
5
2800
3800
4800
5800
6800
7800
8800
9800
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 ANY OTHER USE.
!
CAUTION: The muffler packing on this system MUST be replaced every
6-8 hours of use, or after each moto. Failure to follow recommended
muffler re-packing interval can cause muffler damage and may void
the warranty.
NOTE: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM. WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.
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.
Tools Needed:
Metric Socket Set
Ratchet and Extention
Metric Combination Wrench Set
Allen Bit Set
Torque wrench
Suzuki Service Manual
Installation Steps:
1 Remove stock muffler. (See Fig. 1)
2 Remove heat shield from stock header and install onto
Yoshimura header using stock bolts. (See Fig. 2)
Fig. 1
3 Remove stock header and exhaust port gasket.
NOTE: To remove stock header it is necessary to remove
the radiator hose pictured in Fig. 2. (On 2003-08 models
removal of thermostat is also required). Drain coolant
into a clean container if to be reused (Refer to factory
service manual for detailed instructions). Loosen one of
the hose clamps and disconnect hose.
THERMOSTAT COVER REMOVAL
(Note on 2009 model removal of thermostat is NOT needed.)
• Drain a small amount of engine coolant.
(2%-14%)
• Place a rag under the thermostat case.
• Remove the two 8mm hex headed bolts and the
thermostat cover.
• Remove the thermostat.
He
at
sh
ie
ld
Bo
lts
Remove
Fig. 2
4 Install new exhaust port gasket.
Not supplied (Suzuki Part no. 14181-29E02)
5 Install Yoshimura header using stock header nuts.
Do not tighten nuts at this point.
6 Insert supplied rubber grommet into Yoshimura muffler
mounting bracket.
Fig. 3
Installation Procedures:
7 Insert supplied aluminum spacer into the inside of the
rubber grommet. See parts diagram on page 4 for
orientation.
8 Install Yoshimura tailpipe with muffler onto Yoshimura
header. Install supplied springs onto header-tailpipe
with supplied spring puller tool. (See Fig. 4)
9 Mount muffler to upper chassis mount. Mounting
orientation should go as follows: Supplied bolt,
washer, muffler mounting bracket w/ inserted rubber
grommet, aluminum spacer, aluminum spacer, frame
(See Fig. 5 and Parts Diagram).
10 Torque stock header nuts to to 2.0 kg-m (14.6 lb-ft)
Page 3
Stainless Steel
Muffler Clamp
Aluminum
Spacer
Large Washer
8mm x 65mm
Flange Hex Bolt
Stock Chassis Mounting
Point
Heat
Insulator
Fig. 3
Connect Springs
11 Torque muffler mounting bolt to 2.5 kg-m (18 lb-ft).
12 Reinstall radiator hose and clamp.
13 THERMOSTAT COVER INSTALLATION
• Install the thermostat in the reverse order of
removal.
• Apply engine coolant to the rubber seal on the
thermostat.
• After installing the thermostat, be sure to add
engine coolant.
Heat Shield
Fig. 4
14 Fill radiator with new coolant.
15 Refer to factory service manual for steps on bleeding
the cooling system.
16 Reinstall radiator cap.
17 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.
18 Before starting motorcycle check for proper clearance
between new exhaust system and motorcycle. (i.e.
radiator & fan assembly, rear brake, frame, tire, 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)6349166 / in CA (909)628-4722
Fig. 5
Note: After starting motorcycle, it is normal for
new exhaust system and muffler to smoke
until oil residue burns off.
Part List:
Page 4
#2175152-SA/2175157-SA
Parts Diagram
NO.
DESCRIPTION
1 Yoshimura Header
Titanium Pro
2 Yoshimura Tailpipe
Titanium Pro
3 Stainless Steel Manifold
4 Aluminum Flange
5 TRS Offroad Muffler Assembly
6 Stainless Steel Muffler Clamp
Stainless Steel Sleeve use
Carbon Fiber Sleeve use
7 8mm x 65mm Flange Hex Bolt
8 Large Washer
9 8mm X 43mm Aluminum Spacer
10 2.3" Exhaust Spring
11 1.8" Exhaust Spring
12 3" Exhaust Spring
** Spring Puller Tool
** Muffler Clamp Heat Insulator
** Yoshimura Vinyl Sticker
QTY
1
PART #
2175-704
Carburetor Jetting
Recommendations:
1
1
1
1
1
1
1
1
2
2
2
1
1
1
2175-744
D477SDM
2175ADR
**
CTS087X
CTS087
M8X65H
8MMWASHERL
8MMFS
RACE-SPS-1
RACE-SPX-1
RACE-SPL-1
ST-200
HT SHLD-14A
17029
WITH STOCK AIRBOX:
Install Mikuni main jet #122.5 (Small Round)
AIRBOX WITH SNORKEL CAP REMOVED:
Install Mikuni main jet #145.0 (Small Round)
AIRBOX WITH SNORKEL CAP AND LID
REMOVED:
Install Mikuni main jet #150.0 (Small Round)
NOTE:
Jetting recommendations with a TEC sound
reducing insert installed are the same.
Nuts and Bolts Guide (Actual Size):
8mm x 65mm
Flange Hex Bolt
8mm Large Flat Washer
RESEARCH&DEVELOPMENT OF AMERICA, INC.
4555 CARTER COURT, CHINO CALIF. 91710 · (800)634-9166 · (909)628-4722 · FACSIMILE (909)591-2198
www.yoshimura-rd.com
T E C - S A S p a r k A r r e s t e r C l e a n i n g Information
Parts Diagram
Caution: Muffler can be extremely
hot. Let muffler cool down
before removing spark
arrester.
Note: Read through all instructions
before beginning
disassembly.
Tools Needed:
4mm Allen Key
Wire Brush
Pair of Gloves
Safety Glasses
Cleaning Steps:
1 Using a 4mm Allen key remove the three 6mm x
16mm Button Head Screws located in the muffler end
cap. (See Parts Diagram for location)
2 Remove the end cap, gasket and spark arrester from
the muffler.
NO.
1
2
3
4
5
DESCRIPTION
6 x 1.0mm x 16mm Button Head Screw
4.0" YRD End Cap, Cover
T.E.C. End Cap, Gasket
T.E.C. End Cap, Spark Arrester
Muffler Assembly
QTY
3
1
1
1
1
PART #
M6X16BHS
D46TEC-C
D46TEC-G
TEC-SA
**
3 Using a wire brush remove carbon deposits from
spark arrester screen. Once clean inspect the screen
for excessive wear or damage, if any is found the
spark arrester must be replace. 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, gasket, end cap and 6mm x
16mm screws into muffler assembly. Torque screws
to 1.0 kg-m (7.3 lb-ft)
(Note: It is recommended that a low strength “Loctite” is used on the screws.)