How do I install the Yoshimura R-77 Premium Muffler Repack Kit? (Yoshimura R-77 Premium Muffler Repack Kit Installation Guide)

Answer

manuals.plus

Mar 05, 2025 - 02:20 AM

To install the Yoshimura R-77 Premium Muffler Repack Kit, you will need to follow the steps outlined in the installation guide provided. Here is a summary of the installation process:

1. Removal:
- Start by removing the stock muffler heat shield on the right side.
- Loosen the stock exhaust clamp.
- Carefully remove the stock muffler assembly by removing the muffler mount bolt.
- Repeat these steps for the opposite side.

2. Installation:
- Install the left exhaust clamp (No. 1) to the left tailpipe (No. 6) and the right exhaust clamp (No. 2) to the right tailpipe (No. 7).
- Install the muffler clamp heat shields (No. 9) onto the muffler clamps (No. 5).
- Starting on the right side, install the tailpipe onto the stock header outlet and hand tighten the exhaust clamp.
- Install the muffler onto the tailpipe and slide the muffler clamp (No. 5) along the muffler until it aligns with the front side of the stock muffler mounting point. Secure using the stock hardware.
- Repeat these steps for the opposite side.
- Check for proper alignment of the muffler and adjust if necessary.
- Torque both muffler clamps and exhaust clamps to factory specifications.
- Install the small exhaust springs (No. 8) between the muffler and tailpipe using the supplied spring puller tool (ST-200).
- Install the heat shields (No. 10 and No. 11) using the heat shield screws (No. 12).
- Before starting the vehicle, check for proper clearance between the new exhaust system and rear suspension components.
- Wipe down the muffler and tailpipe with rubbing alcohol to remove oil and fingerprints.
- Note that it is normal for the new exhaust system to emit smoke until oil residue burns off after starting the motorcycle.

Please refer to the complete installation guide provided with the product for detailed instructions and diagrams. If you have any further questions or encounter any issues during the installation process, you can contact Yoshimura's Tech Department at (800) 634-9166 or (909) 628-4722 for assistance.