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

TRS TRI-OVAL PERFORMANCE EXHAUST

SUZUKI 1115 3 6 (2 ,5,7) TRS ZY CLONE S LIP -ON S Y S TE M

1115 2 6 (2 ,5,7) TRS RA CE S LIP -ON S Y S TE M

2001-04
1115 76 (2 ,5,7) TRS TITA NIUM RA CE S LIP ON
GSX-R1000
1115 2 3 5 R22 RA CE S LIP ON

Important technical note: Please see page 3 for detailed

application information.
85
1115265
1115265
150
75
Stock

SAE Corrected Torque (lb-ft)

125
65
SAE Corrected HP

Stock
100
55

75 45

50 35

25
Yoshimura R&D of America 25 Yoshimura R&D of America
2001 SUZUKI GSX-R1000 2001 SUZUKI GSX-R1000
1115265 vs. Stock 1115265 vs. Stock
0 15
2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 2000 4000 6000 8000 10000 12000

RPM x1000 RPM x1000

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

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 FUEL INJECTION 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:
12mm socket
3/8” ratchet and extension
12mm and 14mm wrench
Torque wrench
Installation Steps:
1 Disconnect tail-pipe exhaust valve cables from EXCVA
servo located under fuel tank. (Refer to owner’s service
manual for removal instructions.)

2 Unbolt stock muffler and tail-pipe from passenger foot

rest mount and frame chassis mount, then remove stock
muffler assembly from collector outlet. (See Fig.1)
Fig. 1
3 Slip supplied collector clamp over inlet of Yoshimura tail-
pipe, then slip tail-pipe inlet over stock collector outlet.

4 Mount tail-pipe to inside of chassis mount using stock

bolt and supplied nut. (See Fig.2) Line up chassis mount
on Yoshimura tailpipe with stock chassis mount location.
Torque bolt to 2.5 kg-m (16 lb-ft).

5 Apply heat insulator to inside of muffler clamp and slide

clamp onto muffler. (note direction of clamp in Fig. 3)

6 Mount clamp to outside of stock muffler bracket using

stock bolt, washer, and nut. (see Fig. 3)
Torque bolt to 2.3 kg-m (16 lb-ft) Fig. 2

7 Torque supplied collector clamp to 1.25 kg-m (9 lb-ft).

8 Before starting motorcycle, check for proper clearance

between new exhaust system and motorcycle. (I.e.
Swing-arm, rear brake caliper, cowling, etc.) If any
problem is found, please carefully follow through the
installation steps again. If problem still persists, please
contact Yoshimura tech. Dept. At (800) 634-9166 / in CA
(909) 628-4722.

Note: After starting motorcycle, it is normal for new

muffler to emit smoke until oil residue burns off.
Fig. 3
Installation Procedures: Page 3

2001-2002 GSX-R1000 ONLY

2003-2004 (SEE PAGE 4)

10 It is necessary to properly disable the Suzuki SET

(Suzuki Exhaust Tuning) system by following the
steps listed below. Without properly disabling the
SET system the engine will run in a power limited
fail-safe mode.

11 With ignition in OFF position, remove rider seat and

disconnect engine wire harness connectors from
ECU. (See Fig. 4)

12 Depress rectangular white plastic locking plate on Fig. 4

the 34 pin ECU connector to unlock connector pins.
(See Fig. 5)

13 Pull out black wire with brown stripe. (See Fig. 7&8)

14 Press the protruding two small rectangular white

plastic tabs on ECU connector to lock connector
pins. (See Fig. 6) The white plastic locking plate
should click into place with minimal force when all
remaining pins are bottomed against connector.

15 Tape and secure disconnected wire.

Fig. 5
16 Reconnect engine ECU and reinstall rider seat.
Important technical note: Detailed
application information.

On 2002 GSXR1000s the SET servo, under the tank,

cannot be removed when installing a Yoshimura
exhaust that eliminates the SET valve.

Black Wire with

Brown Stripe

Fig. 6

REAR OF BIKE

ECU BLACK WIRE WITH BROWN STRIPE

Fig. 8

Fig. 7
Installation Procedures: Page 4

2003-2004 GSX-R1000 ONLY

1 With ignition in OFF position, remove rider seat and

disconnect engine wire harness connectors from
ECU. (See Fig. 9)

2 Depress rectangular white plastic locking plate on

the 34 pin ECU connector to unlock connector pins.
(See Fig. 10)

3 Pull out black wire with brown stripe. (See Fig. 12 &
13) Fig. 9

4 Press the protruding two small rectangular white

plastic tabs on ECU connector to lock connector
pins. (See Fig. 11) The white plastic locking plate
should click into place with minimal force when all
remaining pins are bottomed against connector.

5 Tape and secure disconnected wire.

6 Reconnect engine ECU and reinstall rider seat.

Important technical note: Detailed

application information.
Fig. 10

On 2003-2004 GSXR1000s the SET servo, under the

tank, cannot be disconnected when installing a
Yoshimura exhaust that eliminates the SET valve.

Black Wire with

Brown Stripe

Fig. 11
FRONT OF BIKE

ECU BLACK WIRE WITH BROWN STRIPE

Fig. 13

Fig.12
 Part List: Page 5

#111526 (2,5,7)/111536 (2,5,7)/111576 (2,5,7)/1115235

S
S

5 S
3
4
2
6
S = Stock
1
Parts Diagram

NO. DESCRIPTION QTY PART #

1 Yoshimura Slip-On Tailpipe 1 Nuts and Bolts Guide (Actual
Stainless Steel Zyclone and Race Slip-on use 1115-435 Size):
Titanium Slip-on use 1115-735
2 Tri-Oval Muffler Assembly 1 **
3 TRS Stainless Steel Muffler Clamp 1
Stainless Steel or Titanium Sleeve uses CTS083X
Carbon Fiber Sleeve uses CTS083
4 Flanged Nut 1 8MMNUT
5 Stainless Steel Spring 2 RACE-SPS-1 8mm Flange Nut
6 Exhaust Collector Clamp 1 03019127
** TRS Insert Kit 1 TRS-INS-BK
** Heat Insulator 1 HT SHLDTRS
** Yoshimura Vinyl Sticker 1 17100
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 (800) 634-9166 / in CA (909) 628-4722 for more information.
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.

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 (909) 628-4722. 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 sales@yoshimura-rd.com, or fax your question/problems to (909) 591-2198.

To obtain technical information directly from Yoshimura, call (909) 628-4722.