GSX-R1000 EXHAUST KIT

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Timothy Shelton
5 years ago
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1 GSX-R1000 EXHAUST KIT (UNDERTAIL EXHAUST KITS AVAILABLE IN BLACK, WHITE OR SILVER) CAREFULLY READ ALL INSTRUCTIONS BEFORE BEGINNING THE INSTALLATION PROCESS! AS WITH ANY PERFORMANCE MODIFICATION, YOU SHOULD ALWAYS CHECK YOUR WARRANTY BEFORE MAKING ANY MODIFICATIONS TO THE EXHAUST CANISTER OR EMISSIONS DEVICES. HOTBODIES RACING WILL NOT BE HELD RESPONSIBLE FOR ANY MISUSE OR DAMAGES CAUSED BY THE INSTALLATION OF THIS PRODUCT, NOR WILL WE REPLACE ANY STOCK PARTS TO YOUR MOTORCYCLE. HOTBODIES RACING RECOMMENDS THAT YOU HAVE A PROFESSIONAL MECHANIC PERFORM THIS INSTALLATION, THIS PRODUCT WILL REQUIRE RE-MAPPING OF THE FUEL INJECTION TO GET ITS FULL POTENTIAL, WE SUGGEST USING A POWER COMMANDER III AND HAVING IT PROFESSIONALLY TUNED USING A DYNOMETER AND AN EXHAUST GAS ANALYZER. IF YOU CHOOSE TO DO-IT-YOURSELF, WHICH WE DON T RECOMMEND, ALWAYS TAKE APPROPRIATE SAFETY MEASURES WHEN INSTALLING THIS PRODUCT, SUCH AS SAFETY GOGGLES AND LEATHER GLOVES. Your Undertail Exhaust kit should include the following parts: 1 Exhaust canister 1 Mid Pipe (S-Bend) 1 Battery Box 1 Undertail w/ heat shielding 1 Large Hose Clamp 1 #225 Clamp 1 Exhaust bracket 2 Skinny Spacers (Gold Color) 2 Wider Spacers (Gold Color) 1 lock nut 2 small 10mm head bolts 2 Longer Heel Guard Bolts 2 Longer Foot peg bolts 3 Phillips head bolts 2 peices of Heat shield 1) Removing The Stock Parts Before the Installation of Undertail Exhaust Kit a) Carefully remove the right side bodywork panel and inner fairing panels. Save all bolts, washers and plastic rivets for re-installation of these parts. b) Remove drivers seat and Passenger seat/seat cowl. Remove tail section w/ brake light. Save all bolts, washers and plastic rivets for re-installation of these parts. c) Remove Mud flap and stock glove box assembly, leave all electrical components hanging on left side of sub frame. All washers and bolts will NOT be needed for the installation of our product, save for a rainy day. d) Remove the butterfly valve actuating unit from the bike. It is located on the inner edge of the right side subframe near the gas tank. e) loosen Exhaust clamp that is holding the mid pipe to the headers, under the right side foot peg and remove bolt holding the butterfly valve to the frame. f) Remove exhaust hanger bolt (bottom of right side passenger peg) and now you can remove the stock canister and mid pipe from the bike. Read carefully before installation: This exhaust like all after market exhaust has been designed for racing use only. Hot Bodies Racing, our distributors, or our dealers will NOT be responsible for any misuse or improper use or installation of this product. This product has not been presented for D.O.T. certification, always check with your local Department of Motor Vehicles before modifying any aspect of your motorcycle.

2) Route all wiring and fuses on inside left edge subframe as shown in the

You will need 2-8 zip ties plus the stock zip ties to hold all the wiring

If you need clarification on the wiring, check also in step #11.

prevent scratches. Place battery box on top of towel as shown above.

tie through the sensor and the 2 holes on the box, make sure it is securely

5) Attach right side of battery box in the butterfly valve actuating unit

2 2) Route all wiring and fuses on inside left edge subframe as shown in the photos above. You will need 2-8 zip ties plus the stock zip ties to hold all the wiring in place against the sub frame. If you need clarification on the wiring, check also in step #11. 3) Place towel or shop rag on top of rear tire/swingarm and top of shock to prevent scratches. Place battery box on top of towel as shown above. 4) Attach tip over switch to back side of battery box as shown using a zip tie through the sensor and the 2 holes on the box, make sure it is securely fastened with the up arrow on the sensor facing up. 5) Attach right side of battery box in the butterfly valve actuating unit mounting boss using the phillips head bolt and the lock-nut. 6) Place the battery in the box and attach the negative lead to the battery as shown. The battery will be very snug between the box and the main wiring harness.

7) Now pull the left side of the battery box in to position

the small 10mm hex head bolt provided in the kit.

Place the rubber cap on top of screw, it will not fit 100% on

9) Place the electronics in front of the battery as shown.

Seat will hold the ECU firmly against the battery once

11) Your wiring on should look like this after you have

3 7) Now pull the left side of the battery box in to position and mount to the stock glove box mounting location using the the small 10mm hex head bolt provided in the kit. 8) Attach the positive lead to the battery as shown. Place the rubber cap on top of screw, it will not fit 100% on the plug as it did before, this is NOT a problem. 9) Place the electronics in front of the battery as shown. 10) Place the ECU on top of battery as shown. Seat will hold the ECU firmly against the battery once attached. 11) Your wiring on should look like this after you have completed the first 11 steps, double check to make sure nothing is wrong. 12) Place shop rag or towel on the left side of the swing arm to prevent scratches during pipe installation.

13) Place Duct Tape over the forward right side

scratches to the pipe when you install it.

. 15) Slide the exhaust gasket over the stock headers

If you do not have a new Suzuki gasket, you can remove

16) mount the stock exhaust clamp as shown on our new

17) Carefully place pipe into position attach upper

using blue lock tight, do not over tighten, it may spin

4 13) Place Duct Tape over the forward right side passenger peg mounting on the bottom edge to prevent scratches to the pipe when you install it. 14) Remove right side foot controls as shown.. 15) Slide the exhaust gasket over the stock headers as shown. If you do not have a new Suzuki gasket, you can remove the old one from the inside of the stock mid pipe. 16) mount the stock exhaust clamp as shown on our new mid pipe. 17) Carefully place pipe into position as shown.attach upper mount using the smaller 10mm hex head bolt as shown using blue lock tight, do not over tighten, it may spin the mounting if you do. Now remove the tape from the foot peg mounting point. 18) Tighten exhaust clamp on the bottom of the pipe as shown. Remove Rag or towel from the swing arm.

19) Using the spacers and the extension bolts provided in the kit, space the heal guard

Once mounted, you may need to bend the heal guard off the pipe.

Mount the bracket to the bottom side of the mud flap mounting positions using 2 -

21) Slide the canister over the mid pipe and attach using the #225 clamp with the

22) Open the large hose clamp and run around the canister and through the exhaust bracket

5 19) Using the spacers and the extension bolts provided in the kit, space the heal guard and the foot peg and the foot peg off the frame. Once mounted, you may need to bend the heal guard off the pipe. 20) Place canister in position as shown and mount using the exhaust bracket. Mount the bracket to the bottom side of the mud flap mounting positions using 2 - phillips head bolts provided. 21) Slide the canister over the mid pipe and attach using the #225 clamp with the adjustment bolt facing down. 22) Open the large hose clamp and run around the canister and through the exhaust bracket as shown, tighten, but leave loose enough to make adjustments to the canister once the undertail is in place. 23) Place 2 layers of the heat shield on the inside of the stock tail section. Make sure to wrap the heat shield around to the outside edge by at least 1/2. 24) Remove the key lock mechanism from the stock glove box and reinstall into the key lock position on the undertail. Place undertail on the rear tire and re attach the cable lock to the locking mechanism under the seat.

26) Splice your turn signal wires to the signals in the undertail.

On the undertail the red wires are the power wires and the black wires are the ground. * After this modification your undertail is not returnable.

25) *Install license plate brackets to back side of license plate as shown.

6 26) Splice your turn signal wires to the signals in the undertail. On the bike; the black wire is the the left turn, light green wire is the right turn and the black w/ white tracer wire is the ground. On the undertail the red wires are the power wires and the black wires are the ground. * After this modification your undertail is not returnable. Paint is not warrantied against paint chips, flaking or scratches from installation or rocks being thrown from tire into the tray. 25) *Install license plate brackets to back side of license plate as shown. Now hold license plate in desired location on undertail (under the signals), carefully mark and drill holes, install using the two (2) sets of bolts & nuts. c a d b 27) Place the tail section back on the bike. Place new undertail into position on the bike. a) Using the 2 hotbodies screw type plastic rivets insert them into the 2 top mounting holes, do not tighten yet. b) Now using the the 2 stock plastic rivets attach the bottom 2 holes, now tighten the top 2 screw rivets. c) Now using all the stock fasteners re attach the tail section and the driver seat. d) Adjust canister in position and fully tighten the clamp to hold it in place. e) Replace passenger seat or seat cowl. Need Help? If you have any questions about the part(s) or need further help with the installation call us at or us at info@hotbodiesracing.com. This installation does require a professional mechanical aptitude, if in doubt have a professional mechanic perform the installation, 3 hours is the average installation time with dyno tuning.

Part Number: S-H-BAG-8 & S-H-8-RFEN Description: Saddlebags & Rear Fender / Undertail Fitment: Suzuki GSX 1300-R Hayabusa Revision: 1

Part Number: S-H-BAG-8 & S-H-8-RFEN Description: Saddlebags & Rear Fender / Undertail Fitment: 2008-2009 Suzuki GSX 1300-R Hayabusa Revision: 1 Tools Required Phillips head screwdriver Small screwdriver