Yoshimura R77 Dual Race Exhaust System Suzuki Hayabusa 2022 Installation Guide

Yoshimura R77 Dual Race Exhaust System Suzuki Hayabusa 2022

Race Series systems are

• NOT CARB/EPA tail-pipe emissions are compliant.
• NOT street legal.
• For “Closed Course Competition” use only.

You must know how to remove and replace your stock exhaust in order to install this product otherwise have it installed by a professional mechanic. Keep all stock parts from your existing system as some components may be necessary to install your new Yoshimura exhaust depending on the application. Read through all instructions before beginning installation. An exhaust system can be extremely hot. Let the motorcycle cool down before beginning installation. Always wear hand and eye protection and take precautionary measures to avoid injury.

NOTE: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM, WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.

Assembly Diagram

CAUTION: Exhaust system can be extremely hot. Let motorcycle cool down before beginning installation. Always wear hand and eye protection and take precautionary measures to avoid injury.

WARNING: Always properly support vehicle with a stand and/or lift when servicing or performing any work. Unstable vehicles may present dangerous conditions and may cause property damage and/or personal injury.

NOTE: Read through all instructions before beginning installation.

Removal

1. Starting on the right, remove stock muffler heat shield.
2. Loosen stock exhaust clamp.
3. While securely supporting the stock muffler assembly, remove the muffler mount bolt and carefully remove the stock muffler assembly.
   • Note: The stock exhaust gasket will not be used.
4. Repeat steps for opposite side.

Installation

1. Install (No. 1) 03019135, exhaust clamp to (No. 6) 11211-426, left tail pipe. Do not torque at this time.
   • Install (No. 2) 03019143, exhaust clamp to (No.7) 11211-427, right tail pipe. Do not torque at this time.
2. Install (No. 9) HT SHLDR77, muffler clamp heat shields to (No. 5) 1121-MPCR(X), muffler clamps and slide onto both mufflers.
3. Starting on the right, install tail pipe to stock header outlet and hand tighten exhaust clamp.
4. Install muffler onto tail pipe and slide muffler clamp (No.5) 1121-MPCR(X), along the muffler untill it aligns to the front side of the stock muffler mounting point and secure using stock hardware. Do not torque at this time.
   • Note: Stock washer will not be used.
5. Repeat steps for opposite side.
6. Standing at the back of the motorcycle, check for proper alignment of the muffler. Adjust if necessary.
   • Note: To adjust fitment, it may be necessary to rotate the tail pipe or the muffler independently until proper alignment of the muffler is achieved.
7. Once desired alignment is achieved torque both muffler clamps to factory specification.
8. Torque the exhaust clamps to factory specifications.
   • Note: The orientation of the exhaust clamp on the tail pipe may need adjusting to ensure proper installation of the heat shields.
9. Install (No. 8) RACE-SPX-2, small exhaust springs between muffler and tailpipe using the supplied ST-200, spring puller tool.
10. Starting with the left heat shield (No.10) 11211-HSL, install using two (No.12) 116HSB, heat shield screws.
11. Repeat for opposite side.
12. Before starting vehicle, check for proper clearance between new exhaust system and rear suspension (i.e. tire, swingarm, 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 (800) 634-9166 / in CA (909) 628-4722.
13. 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.

RESEARCH&DEVELOPMENT OF AMERICA, INC.

• 5420 DANIELS STREET STE A, CHINO CA., 91710
• (800) 634-9166
• (909) 628-4722
• FAX (909) 591-2198
• www.yoshimura-rd.com

References

• Yoshimura R&D – Yoshimura R&D of America, Inc