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 ·[phone] ·[phone] ·FACSIMILE [phone]
15
25
35
45
55
65
75
85
2800 4800 6800 8800
RPM x1000
SAE Corrected Torque (lb-ft)
1130055
Stock
Yoshimura R&D of America
2003 SUZUKI SV1000S
1130055 vs. Stock
0
10
20
30
40
50
60
70
80
90
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
[phone] / in CA [phone]
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