THIS PRODUCT IS DESIGNED FOR USE IN CLOSED

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
RS -3 OVAL PERFORMANCE EXHAUST SYSTEM
SUZUKI
2003
SV650/S
111105(2,5,7)
STAINLESS STEEL RACE ONLY SYSTEM
55
80
75
50
1111055
65
SAE Corrected HP
60
55
Stock
50
45
40
35
30
25
20
15
Yoshimura R&D of America
2003 SUZUKI SV650S
1111055 vs. Stock
10
5
0
3200
4200
5200
6200
7200
RPM x1000
8200
9200
10200
SAE Corrected Torque (lb-ft)
70
45
1111055
40
Stock
35
30
25
20
Yoshimura R&D of America
2003 SUZUKI SV650S
1111055 vs. Stock
15
10
3200
5200
7200
9200
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:
12mm socket, 11mm (or 7/16") deep sockets
3/8” ratchet and extension
12mm wrench
6mm Allen wrench
Torque wrench
Installation Steps:
1 Remove stock front header. (Unbolt exhaust flange and
loosen exhaust clamp where stock front and rear
header connect. See Fig.1 for fastener locations.)
2 Remove stock muffler and stock rear header. (Loosen
exhaust clamp on rear stock header tube. Unbolt
chassis and muffler mounts. See Fig.2 &3)
Fig. 1
3 Replace old exhaust port gasket on front cylinder with
new exhaust port gasket.
(not supplied - Suzuki part no. 14181-22D01 )
4 Slip 1.5" exhaust clamp over Yoshimura rear header
exhaust port tube.
NOTE: In some cases the stock rear header collector
gasket may stick to the stock rear header, the gasket
must be removed.
5 Install Yoshimura rear header by slipping rear exhaust
port tube onto stock header tube. The chassis mount
on the Yoshimura header should line up to the inside of
the stock chassis mount. Do not tighten exhaust clamp
at this time.
Fig. 2
6 Install chassis mount bolt using stock bolt, washer
and nut. (See fig. 4) Do not tighten bolt at this point.
7 Install Yoshimura front header using stock header
bolts. Torque bolt to 2.0 kg-m (14.5 lb-ft).
8 Install 2.5" exhaust springs where front and rear header
connect.
9 Tighten rear header exhaust clamp to 1.25 kg-m (9 lb-ft).
Fig. 3
Installation Procedures:
Page 3
10 Install Yoshimura tailpipe with muffler.
11 Install 3.5" exhaust springs between tailpipe and
header.
12 Insert heat insulator on inside of muffler clamp
and slide clamp onto muffler. (Note direction of
clamp in Fig. 5)
13 Remove spacer from stock foot peg muffler
mount and install to the outside (See Fig. 5)
14 Mount muffler clamp to stock muffler bracket
using stock bolt, washers and nut.
(See Fig. 5) Torque bolt to 2.5 kg-m (18 lb-ft).
Fig. 4
15 Torque chassis mount bolt to 2.5 kg-m (18 lb-ft).
16 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.
17 Check for proper clearance between new exhaust
system and motorcycle. (i.e. radiator, oil pan,
swing-arm, rear shock linkage 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.
Stock Muffler
Bracket
Stainless Steel
Clamp
Stock Nut and
Washer
Stock Bolt & Washer
Remove Stock Spacer
from Inside and Insert
Outside
Heat
Insulator
Fig. 5
Part List:
Page 4
#111105(2,5,7)
Parts Diagram
NO.
DESCRIPTION
1 Yoshimura Header (Front)
Stainless Steel Race Only
2 Yoshimura Header (Rear)
Stainless Steel Race Only
3 Yoshimura Tailpipe
Stainless Steel Race Only
4 RS-3 Oval Muffler Assembly
5 Stainless Steel Muffler Clamp
Stainless Steel or Titanium Sleeve use
Carbon Fiber Sleeve use
QTY
1
PART #
1111-402
1
1111-403
1
1
1
1111-419
**
COS450S8ASX
COS450S8AS
Nuts and Bolts Guide (Actual Size):
8mm Flange Nut
8mm Large Flat Washer
NO.
6
7
8
9
10
11
12
**
**
**
DESCRIPTION
8mm Washer - Large
8mm Flange Nut
Header Collector Clamp
2.5" Race Spring
3" Race Springs
M12 Copper Crush Washer
12mmX8mm Flanged Hex Head Bolt
Muffler Clamp Heat Insulator
Spring Puller Tool
Yoshimura Vinyl Sticker
QTY
1
1
1
2
4
1
1
1
1
1
PART #
8MMWASHERL
8MMNUT
220-57
RACE-SPS-1
RACE-SPL-1
12MMCW
M12X8H
HT SHLDTRS
ST-200
17029