Yoshimura Honda Rancher 324200C550 User manual

RESEARCH&DEVELOPMENT OF AMERICA, INC.
www.yoshimura-rd.com
5420 DANIELS STREET STE A, CHINO CA., 91710 · [phone] · [phone] · FACSIMILE [phone]
This product is 50-state legal and complies with Federal and State regulations. Any attempts to modify this
product will render it non-compliant with Federal law and void warranty. If modified, the vehicle can no longer be
used on public roads and can only be used for off-highway closed course competition. In the state of California,
it is illegal to modify the emission control system, which includes the fuel injection system of any vehicle.
324200C550
RS2 Full-System Exhaust
Honda Rancher

1
No. Item Description Qty.
1 32420-101 Yoshimura Header 1
2 **** Signature Series Muffler 1
3 39900-RS4BRKT Muffler Hanger Bracket 1
4 Z1022 Rubber Bushing 2
5 M8X60H 8mm x 60mm Flanged Hex Head Bolt 2
6 8MMNUT 8mm Flange Nut 2
7 8MMWASHERL 8mm Large Washer 1
8 8MMWASHERXL 8mm XL Washer 1
9 ALS-003 Aluminum Spacer 1
10 ALS-004 Aluminum Spacer 1
11 ALS-051 Aluminum Spacer 1
12 ALS-050 Aluminum Spacer 2
13 M10X60H 10mm x 60mm Flanged Hex Head Bolt 1
14 10X30WSH 10mm Washer 1
15 10MMFNUT 10mm Flange Nut 1
16 RACE-SPS-1 Medium Exhaust Spring 2
** ST-200 Spring Puller Tool 1
** 347PLUG Yoshimura Wash Plug 1
** 17029 Sticker Kit Sheet 1
2
**** Signature Series muffler replacement part number unavailable. Repair or replacement of Signature Series exhaust systems is only available directly through Yoshimura R&D of America, Inc.
Assembly Diagram
11
12
13
14 15
16
2
3
4
4
5
5
6
6
7
8
9
10

1. Remove seat as per Factory Service / Owners
Manual.
2. Remove the left side center splash guard by the
footpeg. Take precaution when removing plastic
push clips making sure not to damage them
during the removal process.
3. Remove left side cover as per Factory Service /
Owners Manual to gain access to the stock
exhaust system.
4. Remove the O2 sensor from the stock muffler
assembly.
5. Remove the stock header heatshield by
removing the hose clamps securing heatshield
to header.
Note: The stock header heatshield and hose
clamps will be re-used with the Yoshimura
exhaust system.
6. Remove the header nuts.
7. While securely supporting the stock muffler
assembly, carefully remove muffler by sliding
muffler pins out toward the front of the vehicle.
Note: Exhaust port gasket will be re-used with
the Yoshimura exhaust system. Inspect
and replace if necessary.
8. Remove the top rear muffler rubber bushing
from the frame.
Note: The lower front muffler rubber bushing will
be used. Do not remove.
Removal
Installation
2. Install (No. 1) 32420-101, Yoshimura header
using the stock header nuts. Do not torque at
this time.
3. Align header chassis mount to frame and secure
using (No. 13) M10X60H, 10mm bolt, (No. 14)
10X30WSH, 10mm washer, and (No. 15)
10MMFNUT, 10mm nut. See assembly diagram
for proper orientation and order of hardware.
4. Install the stock O2 sensor into (No. 1)
32420-101, Yoshimura header. Torque to factory
specification.
5. Install (No. 4) Z1022, rubber bushing into (No. 3)
39900-RS4BRKT, muffler hanger bracket.
3
1. Install (No. 12) ALS-050, aluminum spacer into
the lower front muffler bushing as shown.
12 12
Frame
Stock Bushing
6. Install (No. 11) ALS-051, aluminum spacer into
frame and secure using (No. 5) M8X60H, bolt,
(No. 8) 8MMWASHERXL, XL washer, (No. 9)
ALS-003, aluminum spacer, and (No. 6)
8MMNUT, flange nut as shown. Do not torque at
this time.
4
3
FRONT
58
Frame
11
3
96
7. Install (No. 4) Z1022, rubber bushing into muffler
bracket.
4
4

8. Install (No. 10) ALS-004, aluminum spacer into
(No. 4) Z1022, rubber bushing in muffler
bracket as shown.
4
410
9. Install Yoshimura muffler assembly by sliding
onto header outlet.
10. Secure Yoshimura muffler to (No. 3) 39900-
RS4BRKT, muffler hanger bracket using the
provided (No. 5) M8X60H, bolt, (No. 7)
8MMWASHERL, washer, and (No. 6) 8MMNUT,
nut.
574
10 3
6
11. Install (No. 16) RACE-SPS-1, medium exhaust
springs between muffler and header connection
using the provided ST-200, spring puller tool.
12. Lift the header up and torque the header nuts to
factory specification.
Note: Check to make sure there is ample
clearance between the header and frame.
13. Torque (No. 5) M8X60H, muffler hanger bracket
bolt and muffler mount bolt to 32.5 Nm
(3.2 kg-m, 24 ft-lb).
14. Torque (No. 13) M10X60H, chassis mount bolt
to 50 Nm (5.0 kg-m, 37 ft-lb).
15. Re-install the stock header heatshield onto
(No. 1) 32420-101, Yoshimura header using the
stock hose clamps.
16. Before starting vehicle, check for proper
clearance between new exhaust system and
rear suspension (i.e. tire, control arms, brakes,
rear shock, and etc.) If any problem is found,
please carefully follow through the installation
steps again. If problem still persists, please call
Yoshimura Tech Department at [phone] /
in CA [phone].
17. It is recommended that the muffler and tailpipe
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.
Note: After starting motorcycle, it is normal for
new exhaust system and muffler to emit
smoke until oil residue burns off.

Dear Yoshimura Customer,
Congratulations and thank you for purchasing a Yoshimura Exhaust System. Over six decades of experience in research and development, state
of the art machinery, materials and craftsmanship of the highest quality all come together in a product of exceptional quality and performance—in
other words, this is the best thing you can put on your bike.
We strive to provide you with a product perfect in fit and finish. However, if you have any problems, please give us a call. We have found that most
fitment issues can be easily resolved by a conversation with one of our knowledgeable and friendly staff. If the issue cannot be resolved this way,
our warranty evaluation program may be the answer. Please take a moment to review our recommendations for the care of your exhaust and our
warranty information.
PLEASE NOTE: If you have any doubts about your exhaust: DO NOT START THE MOTORCYCLE! ONCE AN EXHAUST HAS BEEN USED OR
MODIFIED, IT CANNOT BE RETURNED FOR CREDIT OR EXCHANGE.
EXHAUST SYSTEM MAINTENANCE
Yoshimura Exhaust Systems require very little care and maintenance; here are a few tips:
1. Use mild car/motorcycle soap to clean the exhaust system—do not use any abrasives or degreasers.
2. Clean your exhaust with metal/stainless polish every 1-2 months to retain the luster and remove dirt and grime.
(DO NOT USE POLISH ON “WORKS FINISH” SYSTEMS)
3. Avoid contaminating exhaust surfaces when hot.
4.Your exhaust system will change color (blue, magenta, purple, and/or gold) due to heat; this is normal.
5. Keep all clamps, bolts and other fasteners tight as exhaust systems are susceptible to vibration damage.
6. If you ride in coastal regions or areas that use salt to control ice and snow, wipe the exhaust down after it cools to remove any
possible salt residue, which can result in rusting.
7. If you are storing your motorcycle for the season, wipe the exhaust system down with rubbing alcohol before storage.
8. Head pipes glowing (visible in normal light) may indicate an excessively lean condition that must be corrected.
CARBON FIBER:
Carbon fiber equipped exhaust components require special attention.
The following addresses wear issues directly related to carbon fiber:
1. Keep all clamps, bolts and other fasteners tight. Carbon Fiber is very susceptible to vibration damage.
2. Keep all chemicals and solvents away from the carbon fiber, as they will damage the finish.
3. High temperatures will cause the resin in the carbon fiber to break down. Visual signs such as an amber hue in the resin may be
early signs of heat damage to carbon fiber.
4. Upon seeing amber colored resin, discontinue use. The exhaust system needs to be inspected by a representative from
Yoshimura, for repack, and/or repair. Continued use will cause component failure.
STAINLESS STEEL:
Stainless Steel is not rust proof but is less prone to rusting, staining and pitting; but it is prone to oxidation like all metals.
WORKS FINISH:
1.Works Finish exhaust systems should never be cleaned with abrasives or polishes.
2. Yoshimura recommends using “Bar Keepers Friend” cleaner to remove minor stains.
3.Surface reconditioning services are available to remove scratches and undesirable discoloration due to extreme heat.
Contact Yoshimura Tech Department at [phone] / in CA [phone] for more information.

YOSHIMURA EXHAUST LIMITED WARRANTY
All Yoshimura R&D of America, Inc., exhaust systems carry a one-year limited warranty against defects in workmanship and/or materials.
WHO IS COVERED?
This warranty is provided to the original purchaser of the exhaust system.
WHAT VOIDS THE WARRANTY?
1. Abuse, misuse, improper installation and/or modifications
2. Custom applications
3. No proof of purchase at the time of warranty. Claimant must provide proof of purchase (original receipt or invoice) and a warranty authorization
number (RMA) obtained from Yoshimura.
4. Finishes such as plating or painted surfaces with discoloration or rust due to inclement weather conditions, exposure to salt, exposure to
chemicals, or lack of maintenance by the customer are not covered.
5. International grey-market product purchased through a dealer/distributor not authorized for your country will not be supported by this warranty.
EXTENT OF WARRANTY:
Any defective exhaust system properly returned to Yoshimura will be repaired or replaced by Yoshimura. Yoshimura is not responsible for any
other expense incurred by the customer under the terms of this limited warranty, nor is Yoshimura responsible for any damages either
consequential, incidental, special, contingent or otherwise; or expenses or injury arising directly or indirectly from the use of the exhaust system.
Any exhaust system returned to Yoshimura must be sent at the customers expense along with the proof of purchase and warranty authorization
(RMA). Yoshimura reserves the right to determine whether the terms of the warranty, set out above, have been properly followed. In the event
that the terms are not followed this warranty is void. Yoshimura is the sole determiner of abuse, misuse, installation errors and
modifications—should any of these be found, this warranty is void. The duration of any and all implied warranties are limited to the duration of the
express warranty. All incidental or consequential damages are herby excluded. The warranty gives you specific legal rights and you may have
other rights, which vary from state to state. Some states do not allow the exclusion or limitation of incidental or consequential damages or
limitations on how long an implied warranty lasts, so the above limitations and exclusions may not apply to you.
If you have a fitment or other problem, or are missing a part, please double-check this trouble shooting guide first:
1. Reference your instruction sheet and double-check all drawings and instructions
2. Make sure muffler clamps are installed correctly (refer to instructions diagram). On many models, there is a right and wrong way to install. Also
verify part numbers on headers and tail pipe.
3. Always make sure to install spring-mounted manifolds and flanges on cylinder head prior to installing headers.
4. Always take time to examine problems in detail.
5. When all else fails, call our technical support line at [phone]. The technical line is open 9:00am – 4:30pm Monday through Friday, Pacific
Time. Please have the following information handy: Year/Make/Model of motorcycle, date of purchase, place of purchase, batch dates and part
numbers (found on header and tail-pipe components).
6. Also, feel free to ask through online e-mail at [email protected], or fax your question/problems to [phone].
To obtain technical information directly from Yoshimura, call [phone].
RE-PACKING TIPS
To maintain maximum sound and engine performance the muffler packing will need to be replaced at some time during the muffler’s life. Yoshimura
recommends repacking your muffler at least once a year.
Failure to maintain the muffler packing may cause damage to the muffler and/or void the warranty. Regularly inspect the muffler body for
discoloration, cracks, rattling, or other signs of wear caused by depleted muffler packing. If muffler packing is determined to be depleted or worn,
a Yoshimura muffler re-pack kit is highly recommended to restore the muffler to optimum maximum performance.
Yoshimura offers a 3-5 day turn around (plus transit time) to inspect and refurbish used and damaged mufflers.
For more information on muffler repacking please visit our website at:
http://www.yoshimura-rd.com/muffler-repacking
IMPORTANT TECHNICAL NOTE
Yoshimura recommends on all race exhaust systems, that all spring joints be safety wired. Recommended wire type 304/316
stainless steel with a .032” diameter should be used.