Installation
RESEARCH&DEVELOPMENT OF AMERICA, INC.
5420 DANIELS STREET STE A, CHINO CA., 91710 · (800) 634-9166 · (909) 628-4722 · FACSIMILE (909) 591-2198
www.yoshimura-rd.com
RACE SERIES
Yamaha R3
133200J220
133200J520
(CF/CF)
(SS/CF)
R-77 Stainless Steel Full-System
Race Series systems are:
• NOT CARB/EPA tail-pipe emissions 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. 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: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM, WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.
Assembly Diagram
4
7
6
3
5
8
6
1
2
6
No.
Item
Description
Qty.
1
2
13320-401
13320-419
CRR77M12
SRR77M12
YM7M-MPCA(X)
HT SHLDR77
RACE-SPS-1
8MMNUT
M18X13PLG
INS-04-K
ST-200
17029
Yoshimura Header
Yoshimura Tailpipe
Carbon Fiber Muffler
Stainless Steel Muffler
Muffler Clamp
Muffler Clamp Heatshield
Medium Spring
8mm Flange Nut
O2 Sensor Plug
Low Volume Insert
Spring Puller Tool
Sticker Kit Sheet
1
1
3
4
5
6
7
8
**
**
**
(X) Used for stainless steel muffler canister.
** Not shown in diagram.
2
1
1
1
4
1
1
1
1
1
Removal
1. Remove right lower cowl as per Factory Service
/ Owners Manual.
6. Slide (No. 4) YM7M-MPCA(X), muffler clamp over
(No. 3) muffler. Secure muffler to the outside of
the muffler mount using the stock bolt, washer,
and nut.
2. Loosen exhaust clamp and while securely
supporting the stock muffler assembly, remove
the muffler mount bolt. Carefully remove the
stock muffler assembly.
Muffler
Clamp
Washer
Bolt
3. Remove O2 sensor from the stock header.
4. Remove the header chassis mount bolt.
Note: It may be necessary to remove the two
right rearset bolts to access chassis
mount bolt.
5. While securely supporting the stock header,
remove header nuts and carefully remove the
stock header.
Note: The exhaust port gaskets will be re-used
with the Yoshimura full-system exhaust.
Inspect and replace if necessary.
Installation
1. Install (No. 1) 13320-401, Yoshimura header
using the stock header nuts. Do not torque at this
time.
Note: Check to make sure header flanges are not
overlapping when installing.
2. Install (No. 2) 13320-419, Yoshimura tailpipe onto
(No. 1) 13320-401, header.
3. Secure (No. 2) 13320-419, tailpipe bracket to
chassis using the stock chassis mount bolt and
(No. 7) 8MMNUT, nut. Do not torque at this time.
Note: Tailpipe bracket mounts to the backside of
chassis mount.
4. Install (No. 3) muffler onto (No. 2) 13320-419,
tailpipe.
5. Install (No. 5) HT SHLDR77, muffler clamp
heatshield onto (No. 4) YM7M-MPCA(X), muffler
clamp.
Nut
7. Install (No. 6) RACE-SPS-1, medium exhaust
springs between muffler and tailpipe.
Install (No. 6) RACE-SPS-1, medium exhaust
springs between tailpipe and header.
8. Torque muffler mount bolt to factory specification.
Torque tailpipe chassis mount bolt to factory
specification.
Torque header nuts to factory specification.
9. Re-install the stock O2 sensor into (No. 2)
13320-419, tailpipe.
Note: An additional O2 sensor bung is located on
the tailpipe for performance tuning /
mapping purposes. Install supplied O2
sensor plug if additional O2 sensor will not
be used.
10. Before starting vehicle, check for proper
clearance between new exhaust system and
rear suspension (i.e. tire, control arm, 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.
11. 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 vehicle, it is normal for new
exhaust system and muffler to emit
smoke until oil residue burns off.
5
4
3
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