GP1-R FULL EXHAUST SUZUKI GSX-R600 / GSX-R

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Cory Franklin Williamson
5 years ago
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IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE

1 THIS EXHAUST SYSTEM IS DESIGNED FOR USE IN CLOSED COURSE RACING ONLY, AND IS NOT INTENDED FOR PUBLIC HIGHWAY USE. IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM ON ANY VEHICLE REV. A

2 PARTS INCLUDED Ref. Part Number Description Qty 1) Headpipe #1 1 2) Headpipe #2 1 3) Headpipe #3 1 4) Headpipe #4 1 5) Headpipe Collector 1 6) Muffler Assembly 1 7) Fairing Panel 1 8) Headpipe Collar 4 9) Headpipe Flange 4 10) Muffler Mounting Strap 1 11) Silicone Muffler Strap Isolator 1 12) T-Bolt Clamp, # ) Swivel Spring, Long 12 14) SS M6-1.00x12mm Socket Head Bolt 1 15) M Hex Flange Nut 1 16) M5-0.80x12mm Socket Button Head Bolt 1 17) M Hex Flange Nut 1 18) Exhaust Servo Bracket 1 19) SS M5-0.8x12mm Socket Head Cap Screw, Low 1 20) M x8mm Hex Head Bolt 1 21) mm Copper Crush Washer 1 TOOLS REQUIRED Ref. Description 1) Ratchet 2) 3 & 6 Extension 3) WD40 or Equivalent 4) Spring Pull Tool or Needlenose Pliers 5) High-Temp Silicone Sealant 6) Wire Cutters 7) Medium Strength Thread Locker Ref. Description 8) 4mm Allen Wrench 9) 5mm Allen Wrench 10) 10mm Wrench 11) 12mm Wrench 12) 22mm Wrench 13) 12mm Socket 14) 7/16 Deep Socket

1) Make sure the motorcycle is cool and place securely on a service lift or center stand. 2) Remove both the left and right lower fairings.

Carefully work your way around each fairing, removing fasteners until each side comes free. Set each fairing aside so they will not get damaged.

1) 5) Remove the muffler mounting bolt from the passenger peg mount. Remove the stock muffler assembly from the motorcycle. (Fig.

3 1) Make sure the motorcycle is cool and place securely on a service lift or center stand. 2) Remove both the left and right lower fairings. There are a large number of bolts and push pin plastic fasteners securing the lower fairings to the motorcycle frame and other fairing pieces. Carefully work your way around each fairing, removing fasteners until each side comes free. Set each fairing aside so they will not get damaged. 3) Remove the bolt securing the stock muffler heat shield to the midpipe. Remove the heat shield. Fig. 1 4) Loosen the clamp securing the stock muffler assembly to the headpipe assembly outlet. (Fig. 1) 5) Remove the muffler mounting bolt from the passenger peg mount. Remove the stock muffler assembly from the motorcycle. (Fig. 1) 6) Disconnect the cables attached to the exhaust butterfly valve on the headpipes. (Fig. 2) Fig. 2 7) Remove the o2 sensor from the headpipes, and carefully lift it out of the way for the duration of the installation. (Fig. 2) 8) Locate the left & right upper radiator mount bolts. Remove both bolts. (Fig. 3) NOTE: At this point it is a good idea to tape a clean terry cloth to the rear portion of the front fender, to protect it from damage. Fig. 3

9) Remove the lower radiator mount bolt. (Fig. 4) Pulling the radiator away from the motor will allow more room to remove the stock exhaust system. 10)Remove all 8 headpipe flange mounting bolts.

NOTE: At this point the exhaust may want to fall away from the motor, so be careful when removing the last bolt. Fig. 4 13)Remove the left & right side muffler mounting brackets. (Fig.

To do this, first remove the two bolts securing the rider seat to the frame. Remove the rider seat. (Fig. 7) Fig.

4 9) Remove the lower radiator mount bolt. (Fig. 4) Pulling the radiator away from the motor will allow more room to remove the stock exhaust system. 10)Remove all 8 headpipe flange mounting bolts. (Fig. 5) 11) Remove the right side muffler mounting bolt. (Fig. 2) 12)Remove the left side muffler mounting bolt. (Fig. 6) Remove the complete stock exhaust from the motorcycle. NOTE: At this point the exhaust may want to fall away from the motor, so be careful when removing the last bolt. Fig. 4 13)Remove the left & right side muffler mounting brackets. (Fig. 2, 6) 14)The cables disconnected from the exhaust valve in Step 6 must be disconnected from the servo motor located under the gas tank. To do this, first remove the two bolts securing the rider seat to the frame. Remove the rider seat. (Fig. 7) Fig. 5 15)Remove the two center bolts at the front of the gas tank, just behind the top triple clamp. 16)Carefully lift the gas tank up, and secure using the prop rod located in the tail section trunk area. 17)Follow the exhaust valve cables up from where they were attached to the stock exhaust system, and find the servo motor located under the gas tank near the right side frame rail. Fig. 6

18)Remove the servo motor mounting bolts, and lift it up far enough to access the cables and bracket. (Fig. 8) 19)Disconnect the exhaust valve cables from the servo motor.

8) WARNING: When loosening the cable bracket bolt, secure the bracket using pliers or some equivalent. Forcing the servo motor to turn too far can cause irreparable damage. Fig.

9) 22)Reinstall the servo motor in the original position. Tighten all mounting hardware to factory specification. 23)Lower the gas tank, and secure using the original hardware. Fig.

5 18)Remove the servo motor mounting bolts, and lift it up far enough to access the cables and bracket. (Fig. 8) 19)Disconnect the exhaust valve cables from the servo motor. Feed the cables through the frame and set aside. 20)Remove the cable bracket mounting bolt, and cable bracket from the servo motor. (Fig. 8) WARNING: When loosening the cable bracket bolt, secure the bracket using pliers or some equivalent. Forcing the servo motor to turn too far can cause irreparable damage. Fig. 7 21)Using the provided M5-0.8x12mm Socket Low Head Bolt, apply a small amount of thread locker and install the new Exhaust Servo Bracket as shown. Tighten until secure. (Fig. 9) 22)Reinstall the servo motor in the original position. Tighten all mounting hardware to factory specification. 23)Lower the gas tank, and secure using the original hardware. Fig. 8 24)Reinstall the rider seat, and side cover. 25)Using the original bolts, loosely mount the four Headpipe Collars, and four Headpipe Flanges to the motor. Do not fully tighten the bolts at this time. (Fig. 10) NOTE: To ease header installation, hang one supplied Swivel Spring from each mounting hole location the header flanges (8 total). Fig. 9

Tighten to factory specification. Fig. 10 29)Reinstall the left & right upper radiator mounting bolts. Tighten to factory specification.

6 26)Slide the #1,2,3,4 Headpipes onto the headpipe collars until they are fully seated. (Fig. 11) NOTE: Do not connect the headpipe springs yet. 27)Tighten all headpipe flange bolts to factory specification. Connect all 8 headpipe springs from the flanges to the headpipes. 28)Reinstall the lower radiator support bolt. Tighten to factory specification. Fig )Reinstall the left & right upper radiator mounting bolts. Tighten to factory specification. 30)Slide the supplied Headpipe Collector over all headpipe outlets until the headpipes are fully seated. (Fig. 11, 12) 31)Secure the headpipes to the collector using the remaining four supplied Swivel Springs. (Fig. 11, 12) 32)If equipped w/ O2 sensor: Install the original O2 sensor to the threaded bung on the new Collector Assembly. Tighten until secure. (Fig. 12) If not equipped w/ O2 sensor: Plug the O2 sensor bung using the supplied M x8mm Hex Head Bolt and 12mm Copper Crush Washer. 33)Place the supplied T-bolt clamp onto the notched Muffler Assembly inlet tube. Fig. 11

34)Apply a liberal amount of high temperature silicone sealant to the inside of the Muffler Assembly inlet tube, and slide the muffler assembly over the headpipe collector outlet. (Fig.

35)Remove the white protective covering from the Muffler Strap. Apply the supplied Silicone Muffler Strap Isolator to the inside of the supplied Muffler Strap.

13) NOTE: The gusset on the muffler strap should be away from the motor when the muffler strap is installed.

7 34)Apply a liberal amount of high temperature silicone sealant to the inside of the Muffler Assembly inlet tube, and slide the muffler assembly over the headpipe collector outlet. (Fig. 12, 13) Snug, but do not fully tighten the t-bolt clamp at this time. NOTE: Although not required, you may want to cut off the excess bolt threads protruding from the t-bolt clamp nut. 35)Remove the white protective covering from the Muffler Strap. Apply the supplied Silicone Muffler Strap Isolator to the inside of the supplied Muffler Strap. Work the muffler strap over the muffler until it is positioned near the upper threaded hole on the motorcycle frame from the stock muffler mounting bracket. (Fig. 13) NOTE: The gusset on the muffler strap should be away from the motor when the muffler strap is installed. 36)Place the supplied Muffler Strap against the motorcycle frame, and secure using the original muffler bracket mounting bolt. Using the supplied M5-0.8x12mm Socket Head Bolt, and M5-0.8 hex flange nut, secure the lower support portion of the Muffler Strap. Do not fully tighten at this time. (Fig. 13) NOTE: Apply a small amount of thread locker to the bolt threads prior to securing everything. NOTE: By design, there is a small amount of adjustment in the exhaust system so that the fairing panel and exhaust outlet line up properly. The following steps may need to be performed a few times in order to adjust everything to fit as well as you would like. Fig. 12 Fig. 13 Fig. 14

NOTE: Do not install the rearmost right side fairing mount bolt. That bolt will also be used to secure the new fairing panel.

8 37)Reinstall the lower fairings to the motorcycle. If this is your first attempt at lining the exhaust system up with the fairing panel, consider not installing every lower fairing fastener, just enough to properly position them on the motorcycle. NOTE: Do not install the rearmost right side fairing mount bolt. That bolt will also be used to secure the new fairing panel. 38)Using the original fairing bolt, loosely secure the new Fairing Panel to the motorcycle frame. (Fig. 14) Fig )A small hole must be drilled into the fairing in order to fully secure the fairing panel. First, cover the area of the fairing to be drilled with masking tap. Use a fine point Sharpie or similar permanent marker, and note the position of the rear fairing panel mounting hole onto the motorcycle fairing. (Fig. 15) 40 )Carefully remove the fairing panel and lower right side fairing from the motorcycle. Fig )Using a #4 (0.209 ) drill bit, drill a hole in the fairing where you made your mark. Remove the masking tape and clean up the newly drilled hole if required. (Fig. 16) NOTE: Measure twice, drill once, take your time, there are no do-overs on this step! 42)Reinstall the right side lower motorcycle fairing, and new fairing panel. Secure the rear mounting location of the fairing panel using the supplied M5-0.8x12mm Socket Button head Bolt, and M5-0.8 Hex Flange Nut. Do not fully tighten at this time. (Fig. 14) 43)Make note of the location of the exhaust outlet in comparison to the new Fairing Panel. Remove the Fairing Panel. 44)Adjust the location of the Muffler Assembly so that it will be best centered in the recess in the Fairing Panel.

45)Make sure the T-bolt clamp is covering the notches on the muffler assembly inlet tube. Fully tighten the T-bolt clamp. 46)Fully tighten the muffler strap mounting bolts and nut.

9 45)Make sure the T-bolt clamp is covering the notches on the muffler assembly inlet tube. Fully tighten the T-bolt clamp. 46)Fully tighten the muffler strap mounting bolts and nut. 47)Install the Fairing Panel to the motorcycle one last time. Fully tighten all hardware. 48)Carefully go over all of the lower fairings to make sure that they are installed correctly, and that all fasteners have been properly reinstalled. 49)Clean the new exhaust outlet and fairing panel of all fingerprints and grease. 50)Start your motorcycle and enjoy!

GP1-R FULL EXHAUST SUZUKI GSX-R600 / GSX-R

GP1-R FULL EXHAUST SUZUKI GSX-R600 / GSX-R THIS EXHAUST SYSTEM IS DESIGNED FOR USE IN CLOSED COURSE RACING ONLY, AND IS NOT INTENDED FOR PUBLIC HIGHWAY USE. IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM ON ANY