Suzuki 03-04 GSX-R1000 TiForce exhaust system
Thank you for selecting and purchasing a TiForce exhaust system for your ’ 03-‘04 GSX-R1000. TiForce is the world’s finest titanium exhaust system available today. Please read the following instructions and materials to fully familiarize you with new exhaust system before getting started.
Before Installation
Make sure to detach the connector of the exhaust device
Coat joints on all parts with liquid gasket
Check all accessories have been included
Detach the battery for your safety
For detach and attaching the parts, please refer the service manual
1. Detach the seat, battery, under cowling, tail winker and passenger foot peg.
2. Use standard rod to lift the fuel tank and detach the connector of the exhaust devise servomotor.
(Failure to detach the connector and turn on the main switch, serious damage may occur to the servomotor.)(*See Photo. 1) Detach the standard silencer and wire for the device.
3. Release the coolant and detach the oil cooler.
Detach the standard exhaust pipes after free the oil cooler.
4. Attach an enclosed exhaust pipe to the engine and tighten enough to keep from slipping out of place. (Cylinder number is 1,2,3 and 4 from the engine right side)
*Suggest using new gasket in order to prevent leaking the exhaust.
*Use the standard flange nut and tighten by hand.
5. Attach the joint pipe followed by the tail pipe. Jiggle it and attach the springs.
*Make sure to push into the joint pipe from the right body side to the oil pan. Failure to push into the joint pipe may touch the under cowling.
6. Attach the enclosed silencer stay using by Collar A and Bolt (M8-50mm) to the position of the passengers foot peg of the silencer side. (See Fig. 1)
*For the passenger foot peg users, use collar B and Bolt (M8-110mm).
7. Push silencer into the tail pipe, put the springs, silencer rubber band, band and silencer stay. (Make sure to use rubbered springs to the upper side of the silencer joint.) (M6 x 20mm x 2, M6 nut x 2, M6 washer x 4) (See Fig. 2)
8. Attach the silencer stay enough to keep from loosening using the enclosed bolt (M8-20mm), M8 nut and washer to the silencer stay B assembled in step 6. (See Fig. 1)
9. Check the exhaust pipe, joint pipe and tail pipe not to contact to any one another in any way. And tighten all.
10. Reinstall the battery, radiator and oil cooler. Put coolant and leak the air. (For leaking the air, please refer the service manual.)
11. Check all bots and nuts are tight; start the engine and check for exhaust leak.
12. Attached the enclosed winker to the seat cowling. (Wire by the electronic tap.)
13. Put the heat-resistant tape on both of the closest place to the front pipe #1 (where is the pipe bulge outside) and the joint pipe of the under cowling back side in order to prevent melting the cowling from the pipe heat. (*See Photos.4 and 5)
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