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
RS -3 OFFROAD PERFORMANCE EXHAUST SYSTEM
2175252-SA
2175253-SA
‘03-09 SUZUKI LT-Z400
‘03-05 KAWASAKI KFX400
TITANIUM PRO SLIP-ON WITH CARBON FIBER
TITANIUM PRO SLIP-ON WITH TITANIUM
30
SAE Corrected HP
30
2175600
Stock
25
20
15
10
Yoshimura R&D of America
2003 SUZUKI LTZ-400
2175600 vs. Stock
5
0
2600
3600
4600
5600
6600
RPM x1000
7600
8600
SAE Corrected Torque (lb-ft)
35
25
2175600
Stock
20
15
10
Yoshimura R&D of America
2003 SUZUKI LTZ-400
2175600 vs. Stock
5
2500
3500
4500
5500
6500
7500
8500
RPM x1000
Note: Dyno graphs are for comp arison use only . Actual result s 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 ST ATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM. WHICH INCLUDES
THE CARBURET ORS 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:
10mm & 12mm sockets
3/8” ratchet and extension
10mm & 12mm wrench
4mm & 6mm Allen bit for ratchet
Torque wrench
Suzuki Service Manual
Installation Steps:
1 Remove stock muffler. (See Fig. 1)
2 Remove rubber grommet and insert from stock muffler
chassis mount and install on Yoshimura tailpipe chassis
mount. (See Diagram on Pg. 3)
3 Install supplied collector clamp onto Yoshimura tailpipe.
Fig. 1
4 Slip Yoshimura tailpipe with muffler onto stock header.
5 Bolt tailpipe chassis mount to stock lower chassis
mount using stock bolt and washer. Torque bolt to 2.5
kg-m (18 lb-ft).
6 Apply heat insulator to inside of muffler clamp and slide
clamp onto muffler. (Note direction of clamp in Fig. 3)
NOTE: Mufflers with Carbon Fiber sleeves must have the
supplied spacer installed between the muffler clamp ears
(See Fig. 3)
11 Mount muffler clamp to upper chassis mount using
supplied bolt, washer and spacer. (See Fig. 2)
Fig. 2
12 Torque muffler clamp bolt to 2.5 kg-m (18 lb-ft).
13 Torque collector clamp to to 2.0 kg-m (14.6 lb-ft)
14 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.
15 Before starting motorcycle check for proper clearance
between new exhaust system and motorcycle. (i.e. 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)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.
Spacer for Carbon
Fiber ONLY
Aluminum
Spacer
Stainless Steel
Clamp
Large Washer
8mm x 65mm
Flange Hex Bolt
Stock Chassis
Mounting Point
Heat
Insulator
Fig. 3
Part List:
Page 3
#2175252-SA/2175253-SA
Parts Diagram
NO.
DESCRIPTION
QTY
1 Yoshimura Slip-on Tailpipe
1
Titanium "Pro"
2 RS-3 Offroad Muffler Assembly
1
3 Stainless Steel Muffler Clamp
1
4 8mm x 65mm Flange Hex Bolt
1
5 Large Washer
1
6 8mm X 43mm Aluminum Spacer
1
7 8mm X 4mm Spacer (For 2175252- SA only) 1
8 3 " Exhaust Spring
2
9 Stainless Steel Collector Clamp
1
** Muffler Clamp Heat Insulator
1
** Yoshimura Vinyl Sticker
2
PART #
2175-742
**
COS400S8ASD
M8X65H
8MMWASHERL
8MMFS
8X4SPCR
RACE-SPL
220-55
HT SHLD-14A
17028
Nuts and Bolts Guide (Actual Size):
Carburetor Jetting
Recommendations:
WITH STOCK AIRBOX:
Use Stock Main Jet (#125.0)
WITH AIRBOX SNORKEL CAP REMOVED:
Install Mikuni main jet# 145.0 (Small Round)
WITH AIRBOX LID & SNORKEL CAP
REMOVED:
Install Mikuni main jet# 152.5 (Small Round)
NOTE:
No rejetting is required when install TEC
sound reducing inserts.
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
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.)