RESEARCHampDEVELOPMENT OF AMERICA INC

NOTE IN THE STATE OF CALIFORNIA IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM WHICH INCLUDES THE FUEL INJECTION OF ANY VEHICLE

WWWYOSHIMURA-RDCOM

5420 DANIELS STREET STE A CHINO CA 91710 middot (800) 634-9166 middot (909) 628-4722 middot FAX (909) 591-2198

CAUTION The muffler packing on this system MUST be replaced every 6-8 hours of use or every 1-2 motos Failure to follow recommended muffler re-packing interval can cause muffler damage and may void the warranty

Signature Series systems arebull CARBEPA tail-pipe emissions compliantbull Marked with appropriate EPA noise labelsbull Independent laboratory tested for EPA new vehicle noise compliance

336002G550 (SSSS)

RS-8 Stainless Steel Slip-On

Yamaha Rhino 660

Qualified Manufacturer Declared ldquoReplacement Partrdquo

2005~2007

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

Installation Steps

1 Remove the bed

2 Remove the stock heatshield by removing the four bolts that hold it in place (see Fig 1)

3 Remove the bolts holding the stock muffler in place Then remove the bolts holding the bracket on between the stock header and tailpipe (see Fig 2)

4 Remove stock rubber exhaust damper and stock muffler mounting bracket

5 Re-route taillight wiring harness as shown in (Fig 3)

6 Install right and left side Yoshimura mounting brackets using supplied hardware (see Fig 3) Do not torque at this time

7 Bolt stock front muffler mount to rear muffler mounting bracket using supplied bolts Install rear muffler mounting bracket to the chassis (Fig 3) Do not torque at this time

Note Leave bracket loose to allow free movement while

aligning muffler

8 Insert muffler clamp onto end of Yoshimura tailpipe and install tailpipe onto stock header

9 Insert rubber grommet into front muffler bracket hole Then insert aluminum spacer into rubber grommet (as shown in Fig 3 and 4)

Tools Needed

10mm and 12mm sockets38rdquo ratchet and extension12mm wrenchTorque wrenchDrill14rdquo and 1116rdquodrill bits (or step drill bit)

Fig 1

Fig 2

Fig 3

Bolt tailpipe to headerusing stock bracket and bolts

Reroute cable

10 Slide Yoshimura muffler onto tailpipe and align the muffler bracket with the front and rear muffler mounts Mount using supplied bolts and nuts Do not torque at this time

11 Install supplied exhaust springs on muffler to tailpipe connection

12 Check all clearances around the exhaust system and that muffler is correctly aligned

13 Torque muffler clamp to (165 lb-ft (23 kg-m)

14 Torque tailpipe to header bracket bolts (Fig 3) to 73 lb-ft (10 kg-m)

15 Torque front and rear muffler brackets to 73 lb-ft (10 kg-m)

16 Torque muffler mounting bolts to 165 lb-ft (23 kg-m)

17 Drill holes in stock heatshield using the supplied template (see page 4 for drilling instructions)

18 Reinstall stock heatshield

19 Reinstall bed

20 Before starting vehicle check for proper clearance between new exhaust system and rear suspension (ie tire swing-arm brake rear shock 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

Installation Procedures Page 3

Fig 4

Jetting Recommendations

-Use stock jetting

Note It is illegal to modify the fuel system on any vehicle in the state of California

Page 4Template Instructions

1 Cut template out using a pair of sharp scissors

2 Lay the template out on the stock heatshield making sure that the templates up side is showing Tape template in place

3 Using a center punch make a punch mark in the center of the circle

4 Using a 14rdquo drill bit drill a pilot hole first

5 Using a 1116rdquo drill bit (or a step bit) finish drilling hole size to 1116rdquo (173mm)

6 After drilling make sure all bolt holes line up correctly (as shown in Fig 1)

7 Reinstall heatshield (as shown in Fig 2)

Fig 1

Fig 2

Page 5

NO DESCRIPTION QTY PART

1 Yoshimura Stainless Steel Tailpipe 1 2361-152

2 Yoshimura RS8 Muffler 1 337002G550-CMA

3 Front Muffler Mount Bracket A 1 2361500-BRKTA-R

4 Front Muffler Mount Bracket B 1 2361500-BRKTB-R

5 Rear Muffler Mount Bracket A 1 2361-BRKTA-00

6 Rear Muffler Mount Bracket B 1 2361-BRKTB-00

7 220-59 Collector Clamp 1 22059

8 Medium Race Spring 2 RACE-SPS-1

9 M6 X 10 Stainless Steel Hex Nut 2 6MMNUT

10 8mm Flange Nut 3 8MMNUT

11 8mm Flat Washer Large 1 8MMWASHERL

12 Aluminum Spacer 1 ALS-002

13 Rubber Grommet for Muffler Brackets 1 Z1022

14 6mm X 16mm Socket Head Cap Screw 2 M6X16

15 8mm X 12mm Flanged Hex Head Bolt 2 M8X12H

16 8mm X 25mm Flanged Hex Head Bolt 1 M8X25H

17 8mm X 30mm Flanged Hex Head Bolt 1 M8X30H

18 8mm X 35mm Flanged Hex Head Bolt 1 M8X35H

Spring Puller Tool 1 ST-200

Offroad Endcap Plug 1 347PLUG

Yoshimura Vinyl Sticker 1 17029

336002G550

PARTS DIAGRAM

14

9 10

S

10

10

56

34

15 7

8

12

1113

12

S

S

18

1716

S

S

TH

IS S

IDE

UP

2005-2

007 Y

am

aha R

hin

o 6

60

Heat S

hie

ld Te

mpla

te336002G

550

4

1

2 3

Parts Diagram

NO DESCRIPTION QTY PART

1 6mmX18mm Button Head Cap Screw 1 M6x12BHS

2 Aluminum Ring 1 RS8-RING-1625

3 TEC-SD7 1 TEC-SD7

4 Yoshimura Muffler Assembly 1

RESEARCHampDEVELOPMENT OF AMERICA INC5420 DANIELS STREET SUITE A CHINO CA 91710 middot (800)634-9166 middot (909)628-4722 middot FACSIMILE (909)591-2198

wwwyoshimura-rdcom

Yoshimura S p a r k A r r e s t e r C l e a n i n g Information

Cleaning Steps

Tools Needed

5mm Allen KeyWire BrushPair of GlovesSafety Glasses

1 Using a 5mm Allen key remove the 6mm x 12mm Socket Head Bolt located in the muffler exhaust tip (See Parts Diagram for location)

2 Remove the spark arrester from the muffler

Caution Muffler can be extremely hot Let muffler cool down before removing spark arrester

Note Read through all instructions before beginning disassembly 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 at the same time as muffler re-packing Re-packing is recommended every 1000 miles

CAUTION Gloves and Safety Glasses should be worn while cleaning spark arrester

4 Re-install spark arrester and 6mm x 12mm bolt into muffler assembly Torque bolt to 10 kg-m (73 lb-ft)

NOTE It is highly recommended that a low strength ldquoLoc-titerdquo is used on the bolt

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

Installation Steps

1 Remove the bed

2 Remove the stock heatshield by removing the four bolts that hold it in place (see Fig 1)

3 Remove the bolts holding the stock muffler in place Then remove the bolts holding the bracket on between the stock header and tailpipe (see Fig 2)

4 Remove stock rubber exhaust damper and stock muffler mounting bracket

5 Re-route taillight wiring harness as shown in (Fig 3)

6 Install right and left side Yoshimura mounting brackets using supplied hardware (see Fig 3) Do not torque at this time

7 Bolt stock front muffler mount to rear muffler mounting bracket using supplied bolts Install rear muffler mounting bracket to the chassis (Fig 3) Do not torque at this time

Note Leave bracket loose to allow free movement while

aligning muffler

8 Insert muffler clamp onto end of Yoshimura tailpipe and install tailpipe onto stock header

9 Insert rubber grommet into front muffler bracket hole Then insert aluminum spacer into rubber grommet (as shown in Fig 3 and 4)

Tools Needed

10mm and 12mm sockets38rdquo ratchet and extension12mm wrenchTorque wrenchDrill14rdquo and 1116rdquodrill bits (or step drill bit)

Fig 1

Fig 2

Fig 3

Bolt tailpipe to headerusing stock bracket and bolts

Reroute cable

10 Slide Yoshimura muffler onto tailpipe and align the muffler bracket with the front and rear muffler mounts Mount using supplied bolts and nuts Do not torque at this time

11 Install supplied exhaust springs on muffler to tailpipe connection

12 Check all clearances around the exhaust system and that muffler is correctly aligned

13 Torque muffler clamp to (165 lb-ft (23 kg-m)

14 Torque tailpipe to header bracket bolts (Fig 3) to 73 lb-ft (10 kg-m)

15 Torque front and rear muffler brackets to 73 lb-ft (10 kg-m)

16 Torque muffler mounting bolts to 165 lb-ft (23 kg-m)

17 Drill holes in stock heatshield using the supplied template (see page 4 for drilling instructions)

18 Reinstall stock heatshield

19 Reinstall bed

20 Before starting vehicle check for proper clearance between new exhaust system and rear suspension (ie tire swing-arm brake rear shock 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

Installation Procedures Page 3

Fig 4

Jetting Recommendations

-Use stock jetting

Note It is illegal to modify the fuel system on any vehicle in the state of California

Page 4Template Instructions

1 Cut template out using a pair of sharp scissors

2 Lay the template out on the stock heatshield making sure that the templates up side is showing Tape template in place

3 Using a center punch make a punch mark in the center of the circle

4 Using a 14rdquo drill bit drill a pilot hole first

5 Using a 1116rdquo drill bit (or a step bit) finish drilling hole size to 1116rdquo (173mm)

6 After drilling make sure all bolt holes line up correctly (as shown in Fig 1)

7 Reinstall heatshield (as shown in Fig 2)

Fig 1

Fig 2

Page 5

NO DESCRIPTION QTY PART

1 Yoshimura Stainless Steel Tailpipe 1 2361-152

2 Yoshimura RS8 Muffler 1 337002G550-CMA

3 Front Muffler Mount Bracket A 1 2361500-BRKTA-R

4 Front Muffler Mount Bracket B 1 2361500-BRKTB-R

5 Rear Muffler Mount Bracket A 1 2361-BRKTA-00

6 Rear Muffler Mount Bracket B 1 2361-BRKTB-00

7 220-59 Collector Clamp 1 22059

8 Medium Race Spring 2 RACE-SPS-1

9 M6 X 10 Stainless Steel Hex Nut 2 6MMNUT

10 8mm Flange Nut 3 8MMNUT

11 8mm Flat Washer Large 1 8MMWASHERL

12 Aluminum Spacer 1 ALS-002

13 Rubber Grommet for Muffler Brackets 1 Z1022

14 6mm X 16mm Socket Head Cap Screw 2 M6X16

15 8mm X 12mm Flanged Hex Head Bolt 2 M8X12H

16 8mm X 25mm Flanged Hex Head Bolt 1 M8X25H

17 8mm X 30mm Flanged Hex Head Bolt 1 M8X30H

18 8mm X 35mm Flanged Hex Head Bolt 1 M8X35H

Spring Puller Tool 1 ST-200

Offroad Endcap Plug 1 347PLUG

Yoshimura Vinyl Sticker 1 17029

336002G550

PARTS DIAGRAM

14

9 10

S

10

10

56

34

15 7

8

12

1113

12

S

S

18

1716

S

S

TH

IS S

IDE

UP

2005-2

007 Y

am

aha R

hin

o 6

60

Heat S

hie

ld Te

mpla

te336002G

550

4

1

2 3

Parts Diagram

NO DESCRIPTION QTY PART

1 6mmX18mm Button Head Cap Screw 1 M6x12BHS

2 Aluminum Ring 1 RS8-RING-1625

3 TEC-SD7 1 TEC-SD7

4 Yoshimura Muffler Assembly 1

RESEARCHampDEVELOPMENT OF AMERICA INC5420 DANIELS STREET SUITE A CHINO CA 91710 middot (800)634-9166 middot (909)628-4722 middot FACSIMILE (909)591-2198

wwwyoshimura-rdcom

Yoshimura S p a r k A r r e s t e r C l e a n i n g Information

Cleaning Steps

Tools Needed

5mm Allen KeyWire BrushPair of GlovesSafety Glasses

1 Using a 5mm Allen key remove the 6mm x 12mm Socket Head Bolt located in the muffler exhaust tip (See Parts Diagram for location)

2 Remove the spark arrester from the muffler

Caution Muffler can be extremely hot Let muffler cool down before removing spark arrester

Note Read through all instructions before beginning disassembly 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 at the same time as muffler re-packing Re-packing is recommended every 1000 miles

CAUTION Gloves and Safety Glasses should be worn while cleaning spark arrester

4 Re-install spark arrester and 6mm x 12mm bolt into muffler assembly Torque bolt to 10 kg-m (73 lb-ft)

NOTE It is highly recommended that a low strength ldquoLoc-titerdquo is used on the bolt

10 Slide Yoshimura muffler onto tailpipe and align the muffler bracket with the front and rear muffler mounts Mount using supplied bolts and nuts Do not torque at this time

11 Install supplied exhaust springs on muffler to tailpipe connection

12 Check all clearances around the exhaust system and that muffler is correctly aligned

13 Torque muffler clamp to (165 lb-ft (23 kg-m)

14 Torque tailpipe to header bracket bolts (Fig 3) to 73 lb-ft (10 kg-m)

15 Torque front and rear muffler brackets to 73 lb-ft (10 kg-m)

16 Torque muffler mounting bolts to 165 lb-ft (23 kg-m)

17 Drill holes in stock heatshield using the supplied template (see page 4 for drilling instructions)

18 Reinstall stock heatshield

19 Reinstall bed

20 Before starting vehicle check for proper clearance between new exhaust system and rear suspension (ie tire swing-arm brake rear shock 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

Installation Procedures Page 3

Fig 4

Jetting Recommendations

-Use stock jetting

Note It is illegal to modify the fuel system on any vehicle in the state of California

Page 4Template Instructions

1 Cut template out using a pair of sharp scissors

2 Lay the template out on the stock heatshield making sure that the templates up side is showing Tape template in place

3 Using a center punch make a punch mark in the center of the circle

4 Using a 14rdquo drill bit drill a pilot hole first

5 Using a 1116rdquo drill bit (or a step bit) finish drilling hole size to 1116rdquo (173mm)

6 After drilling make sure all bolt holes line up correctly (as shown in Fig 1)

7 Reinstall heatshield (as shown in Fig 2)

Fig 1

Fig 2

Page 5

NO DESCRIPTION QTY PART

1 Yoshimura Stainless Steel Tailpipe 1 2361-152

2 Yoshimura RS8 Muffler 1 337002G550-CMA

3 Front Muffler Mount Bracket A 1 2361500-BRKTA-R

4 Front Muffler Mount Bracket B 1 2361500-BRKTB-R

5 Rear Muffler Mount Bracket A 1 2361-BRKTA-00

6 Rear Muffler Mount Bracket B 1 2361-BRKTB-00

7 220-59 Collector Clamp 1 22059

8 Medium Race Spring 2 RACE-SPS-1

9 M6 X 10 Stainless Steel Hex Nut 2 6MMNUT

10 8mm Flange Nut 3 8MMNUT

11 8mm Flat Washer Large 1 8MMWASHERL

12 Aluminum Spacer 1 ALS-002

13 Rubber Grommet for Muffler Brackets 1 Z1022

14 6mm X 16mm Socket Head Cap Screw 2 M6X16

15 8mm X 12mm Flanged Hex Head Bolt 2 M8X12H

16 8mm X 25mm Flanged Hex Head Bolt 1 M8X25H

17 8mm X 30mm Flanged Hex Head Bolt 1 M8X30H

18 8mm X 35mm Flanged Hex Head Bolt 1 M8X35H

Spring Puller Tool 1 ST-200

Offroad Endcap Plug 1 347PLUG

Yoshimura Vinyl Sticker 1 17029

336002G550

PARTS DIAGRAM

14

9 10

S

10

10

56

34

15 7

8

12

1113

12

S

S

18

1716

S

S

TH

IS S

IDE

UP

2005-2

007 Y

am

aha R

hin

o 6

60

Heat S

hie

ld Te

mpla

te336002G

550

4

1

2 3

Parts Diagram

NO DESCRIPTION QTY PART

1 6mmX18mm Button Head Cap Screw 1 M6x12BHS

2 Aluminum Ring 1 RS8-RING-1625

3 TEC-SD7 1 TEC-SD7

4 Yoshimura Muffler Assembly 1

RESEARCHampDEVELOPMENT OF AMERICA INC5420 DANIELS STREET SUITE A CHINO CA 91710 middot (800)634-9166 middot (909)628-4722 middot FACSIMILE (909)591-2198

wwwyoshimura-rdcom

Yoshimura S p a r k A r r e s t e r C l e a n i n g Information

Cleaning Steps

Tools Needed

5mm Allen KeyWire BrushPair of GlovesSafety Glasses

1 Using a 5mm Allen key remove the 6mm x 12mm Socket Head Bolt located in the muffler exhaust tip (See Parts Diagram for location)

2 Remove the spark arrester from the muffler

Caution Muffler can be extremely hot Let muffler cool down before removing spark arrester

Note Read through all instructions before beginning disassembly 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 at the same time as muffler re-packing Re-packing is recommended every 1000 miles

CAUTION Gloves and Safety Glasses should be worn while cleaning spark arrester

4 Re-install spark arrester and 6mm x 12mm bolt into muffler assembly Torque bolt to 10 kg-m (73 lb-ft)

NOTE It is highly recommended that a low strength ldquoLoc-titerdquo is used on the bolt

Page 4Template Instructions

1 Cut template out using a pair of sharp scissors

2 Lay the template out on the stock heatshield making sure that the templates up side is showing Tape template in place

3 Using a center punch make a punch mark in the center of the circle

4 Using a 14rdquo drill bit drill a pilot hole first

5 Using a 1116rdquo drill bit (or a step bit) finish drilling hole size to 1116rdquo (173mm)

6 After drilling make sure all bolt holes line up correctly (as shown in Fig 1)

7 Reinstall heatshield (as shown in Fig 2)

Fig 1

Fig 2

Page 5

NO DESCRIPTION QTY PART

1 Yoshimura Stainless Steel Tailpipe 1 2361-152

2 Yoshimura RS8 Muffler 1 337002G550-CMA

3 Front Muffler Mount Bracket A 1 2361500-BRKTA-R

4 Front Muffler Mount Bracket B 1 2361500-BRKTB-R

5 Rear Muffler Mount Bracket A 1 2361-BRKTA-00

6 Rear Muffler Mount Bracket B 1 2361-BRKTB-00

7 220-59 Collector Clamp 1 22059

8 Medium Race Spring 2 RACE-SPS-1

9 M6 X 10 Stainless Steel Hex Nut 2 6MMNUT

10 8mm Flange Nut 3 8MMNUT

11 8mm Flat Washer Large 1 8MMWASHERL

12 Aluminum Spacer 1 ALS-002

13 Rubber Grommet for Muffler Brackets 1 Z1022

14 6mm X 16mm Socket Head Cap Screw 2 M6X16

15 8mm X 12mm Flanged Hex Head Bolt 2 M8X12H

16 8mm X 25mm Flanged Hex Head Bolt 1 M8X25H

17 8mm X 30mm Flanged Hex Head Bolt 1 M8X30H

18 8mm X 35mm Flanged Hex Head Bolt 1 M8X35H

Spring Puller Tool 1 ST-200

Offroad Endcap Plug 1 347PLUG

Yoshimura Vinyl Sticker 1 17029

336002G550

PARTS DIAGRAM

14

9 10

S

10

10

56

34

15 7

8

12

1113

12

S

S

18

1716

S

S

TH

IS S

IDE

UP

2005-2

007 Y

am

aha R

hin

o 6

60

Heat S

hie

ld Te

mpla

te336002G

550

4

1

2 3

Parts Diagram

NO DESCRIPTION QTY PART

1 6mmX18mm Button Head Cap Screw 1 M6x12BHS

2 Aluminum Ring 1 RS8-RING-1625

3 TEC-SD7 1 TEC-SD7

4 Yoshimura Muffler Assembly 1

RESEARCHampDEVELOPMENT OF AMERICA INC5420 DANIELS STREET SUITE A CHINO CA 91710 middot (800)634-9166 middot (909)628-4722 middot FACSIMILE (909)591-2198

wwwyoshimura-rdcom

Yoshimura S p a r k A r r e s t e r C l e a n i n g Information

Cleaning Steps

Tools Needed

5mm Allen KeyWire BrushPair of GlovesSafety Glasses

1 Using a 5mm Allen key remove the 6mm x 12mm Socket Head Bolt located in the muffler exhaust tip (See Parts Diagram for location)

2 Remove the spark arrester from the muffler

Caution Muffler can be extremely hot Let muffler cool down before removing spark arrester

Note Read through all instructions before beginning disassembly 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 at the same time as muffler re-packing Re-packing is recommended every 1000 miles

CAUTION Gloves and Safety Glasses should be worn while cleaning spark arrester

4 Re-install spark arrester and 6mm x 12mm bolt into muffler assembly Torque bolt to 10 kg-m (73 lb-ft)

NOTE It is highly recommended that a low strength ldquoLoc-titerdquo is used on the bolt

Page 5

NO DESCRIPTION QTY PART

1 Yoshimura Stainless Steel Tailpipe 1 2361-152

2 Yoshimura RS8 Muffler 1 337002G550-CMA

3 Front Muffler Mount Bracket A 1 2361500-BRKTA-R

4 Front Muffler Mount Bracket B 1 2361500-BRKTB-R

5 Rear Muffler Mount Bracket A 1 2361-BRKTA-00

6 Rear Muffler Mount Bracket B 1 2361-BRKTB-00

7 220-59 Collector Clamp 1 22059

8 Medium Race Spring 2 RACE-SPS-1

9 M6 X 10 Stainless Steel Hex Nut 2 6MMNUT

10 8mm Flange Nut 3 8MMNUT

11 8mm Flat Washer Large 1 8MMWASHERL

12 Aluminum Spacer 1 ALS-002

13 Rubber Grommet for Muffler Brackets 1 Z1022

14 6mm X 16mm Socket Head Cap Screw 2 M6X16

15 8mm X 12mm Flanged Hex Head Bolt 2 M8X12H

16 8mm X 25mm Flanged Hex Head Bolt 1 M8X25H

17 8mm X 30mm Flanged Hex Head Bolt 1 M8X30H

18 8mm X 35mm Flanged Hex Head Bolt 1 M8X35H

Spring Puller Tool 1 ST-200

Offroad Endcap Plug 1 347PLUG

Yoshimura Vinyl Sticker 1 17029

336002G550

PARTS DIAGRAM

14

9 10

S

10

10

56

34

15 7

8

12

1113

12

S

S

18

1716

S

S

TH

IS S

IDE

UP

2005-2

007 Y

am

aha R

hin

o 6

60

Heat S

hie

ld Te

mpla

te336002G

550

4

1

2 3

Parts Diagram

NO DESCRIPTION QTY PART

1 6mmX18mm Button Head Cap Screw 1 M6x12BHS

2 Aluminum Ring 1 RS8-RING-1625

3 TEC-SD7 1 TEC-SD7

4 Yoshimura Muffler Assembly 1

RESEARCHampDEVELOPMENT OF AMERICA INC5420 DANIELS STREET SUITE A CHINO CA 91710 middot (800)634-9166 middot (909)628-4722 middot FACSIMILE (909)591-2198

wwwyoshimura-rdcom

Yoshimura S p a r k A r r e s t e r C l e a n i n g Information

Cleaning Steps

Tools Needed

5mm Allen KeyWire BrushPair of GlovesSafety Glasses

1 Using a 5mm Allen key remove the 6mm x 12mm Socket Head Bolt located in the muffler exhaust tip (See Parts Diagram for location)

2 Remove the spark arrester from the muffler

Caution Muffler can be extremely hot Let muffler cool down before removing spark arrester

Note Read through all instructions before beginning disassembly 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 at the same time as muffler re-packing Re-packing is recommended every 1000 miles

CAUTION Gloves and Safety Glasses should be worn while cleaning spark arrester

4 Re-install spark arrester and 6mm x 12mm bolt into muffler assembly Torque bolt to 10 kg-m (73 lb-ft)

NOTE It is highly recommended that a low strength ldquoLoc-titerdquo is used on the bolt

TH

IS S

IDE

UP

2005-2

007 Y

am

aha R

hin

o 6

60

Heat S

hie

ld Te

mpla

te336002G

550

4

1

2 3

Parts Diagram

NO DESCRIPTION QTY PART

1 6mmX18mm Button Head Cap Screw 1 M6x12BHS

2 Aluminum Ring 1 RS8-RING-1625

3 TEC-SD7 1 TEC-SD7

4 Yoshimura Muffler Assembly 1

RESEARCHampDEVELOPMENT OF AMERICA INC5420 DANIELS STREET SUITE A CHINO CA 91710 middot (800)634-9166 middot (909)628-4722 middot FACSIMILE (909)591-2198

wwwyoshimura-rdcom

Yoshimura S p a r k A r r e s t e r C l e a n i n g Information

Cleaning Steps

Tools Needed

5mm Allen KeyWire BrushPair of GlovesSafety Glasses

1 Using a 5mm Allen key remove the 6mm x 12mm Socket Head Bolt located in the muffler exhaust tip (See Parts Diagram for location)

2 Remove the spark arrester from the muffler

Caution Muffler can be extremely hot Let muffler cool down before removing spark arrester

Note Read through all instructions before beginning disassembly 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 at the same time as muffler re-packing Re-packing is recommended every 1000 miles

CAUTION Gloves and Safety Glasses should be worn while cleaning spark arrester

4 Re-install spark arrester and 6mm x 12mm bolt into muffler assembly Torque bolt to 10 kg-m (73 lb-ft)

NOTE It is highly recommended that a low strength ldquoLoc-titerdquo is used on the bolt

4

1

2 3

Parts Diagram

NO DESCRIPTION QTY PART

1 6mmX18mm Button Head Cap Screw 1 M6x12BHS

2 Aluminum Ring 1 RS8-RING-1625

3 TEC-SD7 1 TEC-SD7

4 Yoshimura Muffler Assembly 1

RESEARCHampDEVELOPMENT OF AMERICA INC5420 DANIELS STREET SUITE A CHINO CA 91710 middot (800)634-9166 middot (909)628-4722 middot FACSIMILE (909)591-2198

wwwyoshimura-rdcom

Yoshimura S p a r k A r r e s t e r C l e a n i n g Information

Cleaning Steps

Tools Needed

5mm Allen KeyWire BrushPair of GlovesSafety Glasses

1 Using a 5mm Allen key remove the 6mm x 12mm Socket Head Bolt located in the muffler exhaust tip (See Parts Diagram for location)

2 Remove the spark arrester from the muffler

Caution Muffler can be extremely hot Let muffler cool down before removing spark arrester

Note Read through all instructions before beginning disassembly 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 at the same time as muffler re-packing Re-packing is recommended every 1000 miles

CAUTION Gloves and Safety Glasses should be worn while cleaning spark arrester

4 Re-install spark arrester and 6mm x 12mm bolt into muffler assembly Torque bolt to 10 kg-m (73 lb-ft)

NOTE It is highly recommended that a low strength ldquoLoc-titerdquo is used on the bolt