Yoshimura RS-3 User manual

RESEARCH&DEVELOPMENT OF AMERICA, INC.

www.yoshimura-rd.com

RS-3 OVAL PERFORMANCE EXHAUST SYSTEM

SUZUKI

2003-2007

SV1000S

1130 05(2,5,7) S TA INLE S S S TE E L RA CE 3/4 S Y S TE M

Note: Dyno graphs are for comparison use only. Actual results may vary depending on operating and motorcycle condition.

5420 DANIELS STREET STE A, CHINO CA., 91710 ·(800)634-9166 ·(909)628-4722 ·FACSIMILE (909)591-2198

2800 4800 6800 8800

RPM x1000

SAE Corrected Torque (lb-ft)

1130055

Stock

Yoshimura R&D of America

2003 SUZUKI SV1000S

1130055 vs. Stock

100

110

120

3000 4000 5000 6000 7000 8000 9000 10000

RPM x1000

SAE Corrected HP

1130055

Stock

Yoshimura R&D of America

2003 SUZUKI SV1000S

1130055 vs. Stock

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.

! !

Loosen Header Clamp

Installation Procedures: Page 2

Fig. 1

Fig. 2

Fig. 3

Caution: Exhaust system can be extremely hot. Let motorcycle cool down

before beginning installation.

Note: Read through all instructions before beginning installation.

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.

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.

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.

Note: For 2004-2007 models, install supplied bolt,

washer, and aluminum spacer as shown in Fig 5.

Tools Needed:

Socket and Wrench Set

Ratchet Wrench and long extension

6mm Allen wrench

Torque wrench

Rear Collector Clamp

Stock Bolt

and Washer

Stock Muffler

Bracket

Heat

Insulator

Stock Nut

and Washer

Stainless Steel

Clamp

Installation Procedures: Page 3

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).

9 Torque front and rear collector clamps to 1.25 kg-

m (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.

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).

NOTE: Adjustment of the Yoshimura Header may be

necessary. Ensure that the rear shock lower

linkage has sufficient clearance.

14 Torque chassis mount bolt to 2.5 kg-m (18 lb-ft).

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. 6

Fig. 4

Chassis

Mounting

Bracket

Stock Chassis

Mount Bolt with

washer

Stock Nut

Header Mounting

Bracket

Fig. 5

Chassis

Mounting

Bracket

Stock Nut

Header Mounting

Bracket

M8X50H

ALS-014

8mm Washer

Part List: Page 4

Parts Diagram

#113005(2,5,7)

NO. DESCRIPTION QTY PART #

1 Yoshimura Header Collector 1

Stainless Steel Race 1131-410

2 RS-3 Oval Muffler Assembly 1 **

3 Stainless Steel Muffler Clamp 1

Stainless Steel or Titanium Sleeve uses COS450S8BSX

Carbon Fiber Sleeve uses COS450S8BS

4 Header & Collector Clamp 2 220-59

5 8mm Flange Nut 1 8MMNUT

6 2.5" Race Springs 2 RACE-SPS

7 Yoshimura Race Tailpipe 1 1131-419

8 Stainless Steel Clamp 1 20067

9 Aluminum Insert Spacer 1 ALS-014

10 8mm Flat Washer 1 8MMWASHERL

11 8mm x 50mm Flange Bolt 1 M8X50H

** Muffler Clamp Heat Insulator 1 HT SHLDTRS

** Spring Puller Tool 1 ST-200

** Yoshimura Vinyl Sticker 1 17029

Nuts and Bolts Guide (Actual Size):

8mm Flange Nut

8mm x 50mm

Flange Hex Bolt

8mm Large Flat Washer

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