SCORPION ESI - 85 User manual

PART NO.
FIT KITS
FEATURES
BIKE
YEAR
NOTES
scorpion-exhausts.com
FITTING INSTRUCTIONS 1/4
NOTE: ENSURE SCORPION SYSTEM IS CLEAR OF MOVING PARTS AND ALL ORIGINAL FUNCTIONS WORK CORRECTLY.
1300mm Silencer ESC 28
2 43-47mm Band Clamp (Z016.10008)
3 Composite Strap (Z038.10088)
4 Aluminium Collar (Z026.20045)
5 Replacement Servo Wheel (Z007.10955)
6 M6 Split Washer (Z017.10027)
7 Photographic Fitting Instructions
E-MARK ROUND N/A
E-MARK OVAL e4 2169
ISSUE NO. 9
DATE 02/09/08
AUTHORISED S.Northrop
CHECKED
SUZUKI GSXR 1000 K5
2005 - 2006
Where not supplied use original ttings
ESI - 85
OVAL Z039.11193
DB KILLER Z038.10120
Box: PLOCK 1
A B
CD
A,B) Remove front seat (bolts both
sides)
C) Remove black plastic side panels
from both sides of the bike
D)Remove front tank bolts (x2)
and nd tank support stay under
pillion seat
1
2
4
3
6
5

PART NO.
FIT KITS
FEATURES
BIKE
YEAR
NOTES
scorpion-exhausts.com
FITTING INSTRUCTIONS 2/4
SUZUKI GSXR 1000 K5
2005 - 2006
Where not supplied use original ttings
ESI - 85
OVAL Z039.11193
DB KILLER Z038.10120
Box: PLOCK 1
E) Support tank with stay, allowing
access to wiring underneath rear
of tank
F) Disconnect both sets of cables
going to servo motor
G, H) Remove bracket supporting
servo motor (bolts x2)
I) Completely remove the bracket,
noting the orientation of both
holes
J) Remove footrest assembly (bolts
x2)
K) Remove brake uid reservoir
and hang loose with the footrest
assembly
L) Disconnect rear brake switch
and spring
CONTINUED FROM OVERLEAF:
E F
GH
I J
KL

PART NO.
FIT KITS
FEATURES
BIKE
YEAR
NOTES
scorpion-exhausts.com
FITTING INSTRUCTIONS 3/4
SUZUKI GSXR 1000 K5
2005 - 2006
Where not supplied use original ttings
ESI - 85
OVAL Z039.11193
DB KILLER Z038.10120
Box: PLOCK 1
M) Remove bolt holding cable
clamp behind footrest
N) Drop servo motor from behind
sub-frame
O) Remove hexagonal wheel from
shaft, retaining OE bolt. Do not
turn shaft, whilst unbolting
P) Remove cables from the wheel,
but leave attached at the exhaust
valve
Q) The replacement wheel comes
with spring washer and aluminium
collar that is secured in place with
OE bolt.
TIGHTEN TO 5ft/lb USING A
TORQUE WRENCH
The replacement wheel must
be tted with the etched letters
“UP” also add a small amount of
“LOCTITE” to servo bolt.
R) Re-t the servo motor & bracket
and reconnect the power cables
S) Remove the three bolts retaining
the OE exhaust system
T) The lower clamp bolt is hidden
behind the bellypan fairing
CONTINUED FROM OVERLEAF:
N
OP
R
ST
N
Q
MM

PART NO.
FIT KITS
FEATURES
BIKE
YEAR
NOTES
FITTING INSTRUCTIONS 4/4
SUZUKI GSXR 1000 K5
2005 - 2006
Where not supplied use original ttings
ESI - 85
OVAL Z039.11193
DB KILLER Z038.10120
Box: PLOCK 1
U) Remove OE exhaust mounting
bolt
V) Completely remove the whole
OE exhaust
W) Re-t the footrest assembly and
brake uid reservoir
X) Fit the clamp over Scorpion
connecting pipe before sliding into
position
Y,Z) Fit the Scorpion Silencer to rear
footrest hanger with OE bolt
ALIGN SCORPION SILENCER AND
TIGHTEN APPROPRIATE
NUTS, BOLTS & CLAMPS
REFIT ALL PARTS IN REVERSE
ORDER Ensure all cables and any
tments are secured safely and
all original functions work
correctly prior to use.
CONTINUED FROM OVERLEAF:
U V
WX
Y Z
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