REEARCH&DEVELOPMENT OF AMERICA, INC. 5420 DANIEL TREET TE A, CHINO CA, 91710 (800)634-9166 (909)628-4722 FACIMILE (909)591-2198 www.yoshimura-rd.com YOHIMURA PERFORMANCE EXHAUT YTEM 2008-2010 POLARI RZR 800 2540500 R8 3/4 YTEM WITH ALUM INUM LEEVE THI PRODUCT I DEIGNED FOR UE IN CLOED COURE! RACING AND I NOT INTENDED FOR ANY OTHER UE.! CAUTION: The muffler packing on this system MUT 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 TATE OF CALIFORNIA, IT I ILLEGAL TO MODIFY THE EMIION CONTROL YTEM, WHICH INCLUDE THE CARBURETOR OF ANY VEHICLE.
Installation Procedures: Page 2 Caution: Exhaust system can be extremely hot. Let vehicle 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: tandard ocket et Metric ocket et tandard Combination Wrench et Metric Combination Wrench et 3/8 Ratchet and Extension Torx Bits Torque Wrench Installation teps: 1. Remove the bed and rear bumper. Fig 1 2. Remove the springs that connect the stock midpipe to the stock header and frame (see Fig. 1 and Fig. 2 for spring locations). 3. Loosen the stock collector clamp that connects the stock muffler to the stock midpipe (see Fig. 2). 4. Remove the stock muffler and stock midpipe through the drivers side of the chassis. 5. Transfer the stock rubber stoppers from the stock midpipe to the Yoshimura midpipe using the supplied 5/16 nuts to secure them (see Fig. 4). Fig 2 6. Torque the 5/16 nuts that secure the stock rubber stoppers to 2.5 kgf-m (18 lb-ft). 7. Transfer the stock heatshield from the stock midpipe to the Yoshimura midpipe using the supplied 6mm button head cap screws and washers. 8. Install the Yoshimura midpipe onto the stock header using the stock springs. Connect the Yoshimura midpipe to the frame using the stock springs. 9. lide the supplied exhaust clamp over the inlet of the Yoshimura tailpipe. 10. Insert supplied exhaust gasket into tailpipe. Insert the Yoshimura tailpipe into the Yoshimura muffler while inside the frame. lide onto outlet of Yoshimura midpipe. tock Rubber topper tock Nut Yoshimura Midpipe Bracket upplied 5/16 Nut Fig 4
Installation Procedures: Page 3 NOTE: Due to tight clearances between the frame and the Yoshimura exhaust system, the Yoshimura tailpipe and Yoshimura muffler must be installed at the same time in the frame.. Insert supplied spacer into rubber grommet then install into frame. Mount Yoshimura muffler to frame using the supplied bolt, washer, and nut (ee Parts Diagram on page 4). Fuel Injection Mapping uggestions: For maximum performance, fuel injection mapping is recommended for competition use only. Note: It is illegal to modify the fuel injection system of any vehicle in the state of California. 12. Connect the Yoshimura muffler to the Yoshimura tailpipe using the supplied exhaust springs. 13. Install support pins into muffler by sliding them through rubber grommets. Install nut onto pin, then screw into muffler. Adjust to get best fit and tighten. 14. Torque the muffler mount bolt to 2.9 kg-m (21 lb-ft). 15. Torque the supplied exhaust clamp to 1.25 kg-m (9 lbft). NOTE: 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. 16. Reinstall the bed and rear bumper. 17. Before starting the vehicle, check for proper clearance between the new exhaust system and rear suspension (i.e. tires, swing-arm, brakes, rear shocks, frame, etc). If any problem is found, please carefully follow through the installation steps again. If problem still persists, please call Yoshimura technical department at (800) 634-9166 / in CA (909) 628-4722. NOTE: After starting the vehicle, it is normal for a new exhaust system and muffler to emit smoke until oil residue burns off.
Part List: Page 4 2540500 1 16 10 2 14 9 8 10 7 13 15 12 4 3 6 5 = TOCK PART DIAGRAM NO. DECRIPTION QTY PART # 1 tainless teel Clamp 1 20062 2 Yoshimura Midpipe 1 2540-104 3 5/16" Flange Nut 2 5/16-18NUT 4 Yoshimura Tailpipe 1 2540-144 5 Yoshimura Muffler Assembly with Aluminum leeve 1 2540500-CMA 6 mall Exhaust prings 2 RACE-PX-1 7 10mm X 35mm Bolt 1 M10X35H 8 10mmX30mm Washer 1 10X30WH 9 10mm Flanged Nut 1 10MMFNUT 10 6mm Flat Washer 4 6MMWAHER 6mmX10mm Button Head crew 4 M6X10BH 12 8mm Flange Nut 2 8MMNUT 13 Rubber Grommet 1 Z1031 14 Rubber Grommet pacer 1 Z1031-P-B 15 Threaded Rod M8x145mm 1 M8X145TR 16 Threaded Rod M8x130mm 1 M8X130TR ** Muffler Gasket: HON 18391-429-010 1 16-5569 ** Offroad Endcap Plug 1 347PLUG ** pring Puller Tool 1 T-200 ** Yoshimura Vinyl ticker 1 17029
REEARCH&DEVELOPMENT OF AMERICA, INC. 5420 DANIEL TREET UITE A, CHINO, CA 91710 (800)634-9166 (909)628-4722 FACIMILE (909)591-2198 www.yoshimura-rd.com Yoshimura p a r k A r r e s t e r C l e a n i n g Information 4 2 3 1 Caution: Muffler can be extremely hot. Let muffler cool down before removing spark arrester. Note: Tools Needed: 5mm Allen Key Wire Brush Pair of Gloves afety Glasses Read through all instructions before beginning disassembly. Cleaning teps: 1 Using a 5mm Allen key, remove the 6mm x 12mm ocket Head Bolt located in the muffler exhaust tip. (ee Parts Diagram for location) 2 Remove the spark arrester from the muffler. Parts Diagram NO. DECRIPTION QTY PART # 1 6mmX18mm Button Head Cap crew 1 M6x18BH 2 Aluminum Ring 1 R8-RING-1625 3 TEC-D7 1 TEC-D7 4 Yoshimura Muffler Assembly 1 ** 3 Using a wire brush, remove carbon deposits from spark arrester screen. Inspect the screen for excessive wear or damage. If spark arrester is excessively worn or damaged, the spark arrester must be replaced. Cleaning and inspection should be performed after every 60 hours of use. CAUTION: Gloves and afety Glasses should be worn while cleaning spark arrester. 4 Re-install spark arrester and 6mm x 12mm bolt into muffler assembly. Torque bolt to 1.0 kg-m (7.3 lb-ft). NOTE: It is highly recommended that a low strength Loc-tite is used on the bolt.