EA47 YOSHIMURA Race Series Yamaha MT-09 AT2 Stainless Steel Full-System Installation Guide

EA47 YOSHIMURA Race Series Yamaha MT-09 AT2 Stainless Steel Full-System

Race Series systems are:

• NOT CARB/EPA tail-pipe emissions are 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 the motorcycle cool down before beginning installation. Always wear hand and eye protection and take precautionary measures to avoid injury.

PARTS

Removal

1. Remove the O2 sensor from the stock header.

2. Remove header nuts.

3. Remove the stock radiator bracket by removing the stock bolt.
   Note: Place bracket and bolt aside as it will be reinstalled later.

4. While securely supporting the muffler, remove the muffler chassis bolts and carefully remove the stock muffler/header assembly.
   Note: Exhaust port gaskets will be re-used with the Yoshimura exhaust system. Inspect and replace if necessary.

5. Remove the stock exhaust bracket by locating the stock bolt and nut near the left foot peg and to left of the muffler chassis bolt.
   Note: The stock bolt and nut securing the stock bracket will be re-used with the Yoshimura exhaust system.

Installation

1. Remove the two right-rear oil pan bolts and install the 13992-TPBKT-1, tailpipe bracket using the stock oil pan bolts. See assembly diagram for proper orientation of tailpipe bracket.
2. Install 13992-401-1D, Yoshimura header using the stock header nuts. Do not torque at this time.
3. Using an M8X20H, 8mm bolt and an 8MMNUT, 8mm flange nut install the 13992-401-1D, Yoshimura header onto the backside of the 13992-TPBKT-1, oil pan bracket. Do not torque at this time.
4. Install Z1022, rubber grommet, and ALS-003, aluminum spacer onto 13992-MBKT-1, muffler bracket.
5. Using the stock hardware from the stock exhaust bracket, place the 10X25X30SPCR, aluminum chassis spacer where the stock exhaust bracket previously was and slide the stock bolt back in to hold it in place. Then take the 13992-MBKT-1, muffler bracket and locate the two bolt holes with the stock bolt and nut on the bike as shown in the photo below. Secure using stock bolt and nut and tighten to factory specifications.
6. Install 13992AP520-RMA, muffler onto 13992- 401-1D, Yoshimura header and secure to the backside of 13992-MBKT-1, muffler bracket using M8X30H, 8mm hex bolt and 8MMNUT, 8mm flange nut.
7. Install RACE-SPX-2, small spring onto the 13992AP520-RMA, muffler, and 13992-401-1D, Yoshimura header using ST-200, spring puller.
8. Torque muffler bracket bolts, oil pan bracket bolts, and header nuts to factory specification. Reinstall radiator bracket and torque stock bolt to factory specification.
9. Remove the left radiator cover to expose the O2 sensor wire. Locate the mounting clip and two cable tie locations and remove the clip and cut the two cable ties to free the O2 sensor wire, as shown below.
10. Route the O2 Sensor wire through the top of the radiator and behind the mounting brackets.
11. Remove the right radiator cover and route the O2 sensor wire down the wire channel and connect B6450, the O2 sensor extension wire.
12. Install OXYBA12X125SS, O2 sensor adaptor onto the 13992-401-1D, Yoshimura header. Then install the stock O2 sensor and tighten to factory specification.
13. Reinstall left and right radiator covers using opposite steps of removal.
14. Before starting the vehicle, check for proper clearance between new exhaust system and rear suspension (i.e. tire, swingarm, brakes, rear shock, and etc.) If any problem is found, please carefully follow through the installation steps again. If the problem still persists, please call Yoshimura Tech Department at 800-634-9166 / in CA 909-628-4722.
15. 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 the vehicle, it is normal for new exhaust system and muffler to emit smoke until oil residue burns off.

Care & Maintenance

Before starting the vehicle, clean the pipe thoroughly using a soft cloth and rubbing alcohol to remove any oil and fingerprints. The color of the exhaust will change once the system has gone through a heat cycle of 15 minutes or more. Color will vary depending on lean/rich conditions. Clean using a soft cloth and soap. Do not use abrasive materials as it will scratch the surface. Surface reconditioning services are available to remove scratches and undesirable discoloration due to extreme heat. Contact Yoshimura Tech Department at 800-634-9166 / in CA (909) 628- 4722 for more information.

RESEARCH&DEVELOPMENT OF AMERICA, INC.
www.yoshimura-rd.com
5420 DANIELS STREET STE A, CHINO CA., 91710 · 800-634-9166 · 909-628-4722 · FAX 909-591-2198

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