THIS PRODUCT IS DESIGNED FOR USE IN CLOSED COURSE RACING AND IS NOT INTENDED FOR ANY OTHER USE.

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1 RESEARCH&DEVELOPMENT OF AMERICA, INC DANIELS STREET STE A, CHINO CA (800) (909) FACSIMILE (909) OFF-ROAD PERFORMANCE EXHAUST SYSTEM Yamaha YZ450F TITANIUM PRO FULL SYSTEM WITH CARBON FIBER SLEEVE TITANIUM PRO FULL SYSTEM WITH TITANIUM SLEEVE NOTE: THIS SYSTEM IS DESIGNED FOR USE IN CLOSED COURSE COMPETITION AND IS NOT INTENDED FOR ANY OTHER USE.! THIS PRODUCT IS DESIGNED FOR USE IN CLOSED COURSE RACING AND IS NOT INTENDED FOR ANY OTHER USE.! CAUTION: The muffler packing on this system MUST be replaced every 6-8 hours of use, or after each moto. Failure to follow recommended muffler re-packing interval can cause muffler damage and may void the warranty. NOTE: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM, WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.

2 Installation Procedures: Page 2 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. Note: Read through all instructions before beginning installation. Tools Needed: 8mm, 10mm, and 12mm Sockets Ratchet Wrench and Extension Torque Wrench Spring Puller Tool Installation Steps: 1 Remove right rear number plate (see Fig. 1 for bolt locations). 2 Remove stock exhaust system (see Fig. 2) Remove exhaust port gasket. Titanium system is designed to have the exhaust manifold bolted directly to the cylinder head without the use of the stock exhaust port gasket. NOTE: Install springs onto aluminum flange prior to installing flange and manifold. 4 Install Yoshimura exhaust manifold and flange using stock header nuts. 5 Torque header nuts to 1.0 kg-m (7. lb-ft). 6 Install Yoshimura header onto exhaust manifold using supplied springs (use supplied spring puller tool). Ensure header is fully seated onto exhaust manifold. 7 Install supplied rubber grommet into aluminum muffler mounting bracket. Install aluminum insert into rubber grommet (make sure shoulder of aluminum insert faces toward the frame, see Fig. ). 8 Install Yoshimura tailpipe and muffler onto Yoshimura header. 9 Install stock muffler mount bolt and washer. Install stock chassis mount bolt. Fig. 1 Muffler Mount Fig. 2 Aluminum Insert Rubber Grommet Toward Frame Fig.

3 Installation Procedures: Page 10 Check exhaust for proper position and clearance and adjust if necessary. 11 Torque muffler mount bolt to 2.5 kg-m (18 lb-ft). 12 Torque chassis mount bolt to 2.5 kg-m (18 lb-ft). 1 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. 14 Before starting motorcycle, check for proper clearance between new exhaust system and rear suspension (i.e. tire, swingarm, brake, rear shock, 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) or (909) in California. 15 Reinstall number plate. NOTE: After starting motorcycle, it is normal for new exhaust system and muffler to emit smoke until oil residue burns off.

4 Part List: Page 4 # / S S S S = STOCK Parts Diagram NO. DESCRIPTION QTY PART # 1 Stainless Steel Exhaust Manifold 1 275SDM 2 Aluminum Flange 1 286ADR-TI Medium Exhaust Spring 4 RACE-SPS-1 4 Yoshimura Titanium Header Yoshimura Titanium Tailpipe Yoshimura Race Muffler 1 with Carbon Fiber Sleeve RMA with Titanium Sleeve RMA 7 Aluminum Insert for Rubber Grommet 1 ALS-002 ** Muffler Mount Rubber Grommet 1 Z1022 ** Spring Puller Tool 1 ST-200 ** Yoshimura Vinyl Sticker Stock Jetting YZ450F 160 Main 45 Pilot Needle rd Position From Top Carburetor Jetting Recommendations: 1. Remove carburetor from vehicle; refer to Yamaha Service Manual. 2. Install main jet #165 (Not Supplied). Install pilot jet #48 (Not Supplied) 4. Move needle to 4th position from top. 5. Re-install carburetor in accordance with Yamaha Service manual.

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6 RESEARCH&DEVELOPMENT OF AMERICA, INC DANIELS STREET SUITE A, CHINO, CA (800) (909) FACSIMILE (909) Low Volume Insert Removal/Installation Parts Diagram Tools Needed: 4mm Allen Key Wire Brush Pair of Gloves Safety Glasses NO. DESCRIPTION QTY PART # 1 6mm X 20mm Button Head Cap Screw 1 M6X18BHS 2 RS2 Ring 1.500" 1 DS4-RING-1500 RS2 Low Volume Insert 1 INS-J 4 Yoshimura Exhaust ** ** Caution: Muffler can be extremely hot. Let muffler cool down before removing low volume insert. Note: Read through all instructions before beginning disassembly. Instructions: CAUTION: Gloves and safety glasses should be worn while cleaning spark arrester. 1 Remove muffler from tailpipe. 2 Insert the front insert into the tailpipe. Reinstall the muffler. 4 Insert the rear insert into the end of the muffler and secure using the small allen head bolt. NOTE: It is recommended that a low strength Loc-tite is used on the small allen head bolt.