Installation
Guide 2003-04 Suzuki GSXR1000
Congratulations on the purchase of your new TaylorMade under seat exhaust kit. A major feature of the new GSXR style is the sleek, skinny tail section and your new under seat exhaust has been designed to complement and enhance the original design. To achieve the unique, TaylorMade look it has been necessary to pack a lot of components into that skinny tail section so please read the installation guide before attacking your bike!
Any competent mechanic with basic tools can install the kit but if you have any doubts in your mechanical abilities entrust installation to an experienced workshop. Time to fit is approximately 3-5 hours depending on familiarity. All directions are given are as if you are sat on the bike: e.g. left = gear change side. Tools required: Large-head Philips screwdriver, long straight blade screwdriver, metric socket head keys, 13,12,10, and 8mm wrenches, high temperature RTV plus thread lock.
Your TaylorMade exhaust is fitted in three stages. First you will need to remove your Suzuki's battery tray and ancillaries. Stage Two is preparation of various components. The final stage is to install the new battery tray, passenger subframe and mufflers. Please read the instructions carefully as they will help you get the job done quicker and more easily.
Stage One - Disassembly
1. Remove two bolts at front of gas tank, lift and support with the stock prop located in the tail unit.
2. Remove passenger seat pad and unbolt rider's seat
3. Disconnect battery and remove
4. Remove Tail Unit:
a) disconnect taillight,
b) unbolt rear fender and license plate mount,
c) disconnect seat lock cable,
d) detach tail unit from under tray by removing the plastic push-fit connectors. These are easily damaged. Operation is shown below:
e) remove two mounting bolts at rear of seat unit, pull front ‘ears' out of rubber grommets on subframe and pull away to the rear.
5. Remove passenger seat lock from sub frame.
6) Pull under tray to rear and remove.
7) Unscrew bolt on underside of battery tray securing tray to aluminium cross brace under passenger sub frame. Unbolt and remove passenger sub frame and cross brace.
8) Unbolt aluminium cross brace under riders seat and remove.
9) Pull relays and ECU from their mounts on the battery tray and let the main wiring harness hang over the left hand frame rail.
10) Pull rubber mat from battery location and remove bolt. Pull battery tray back to expose tip cut out switch at front of tray. Pull switch from mounts and remove battery tray.
11) Unbolt and remove the stock muffler. Unbolt headers from bracket behind and below riders right hand foot peg.
12) Exhaust Valve Servo Motor:
a) disconnect servo motor from main wiring harness by separating two connectors located on main frame rear shock mount under the gas tank,
b) remove two socket head bolts reached through access holes in front right hand sub frame rail,
c) remove rear brake heel guard and replace bolts securing rear brake master cylinder,
d) unbolt riders right hand foot rest hanger,
e) remove bracket retaining exhaust valve operating cables located between footrest mounting lugs on the main frame,
f) unbolt rear brake remote reservoir,
g) pull exhaust valve servo motor out of frame,
h) replace rear brake remote reservoir
13) Remove mounting screw for belly pan located at the bottom of the main frame and loosen the muffler clamp. Remove exhaust-mounting bolt to frame located below the rider's footrest. Remove nut and bolt (save nut for use later) clamping muffler to passenger footrest hanger and pull away muffler complete with exhaust valve.
14) Unhook rear brake line from hugger and remove hugger.
Stage Two – Preparation
Hugger
Remove plastic brake line retainer. File/cut/grind guide slot for line to run inside hugger
Tail Unit
Remove taillight. Scuff inside of carbon trim piece with sand paper. Clean any oil and/or grease from the rear of the tail unit - brake cleaner is very handy for this job. Offer up the trim piece to the tail unit and note the area of contact between the two pieces. Smear the area of contact with RTV both on the tail section and the inside of the trim piece. Place carbon trim in position and replace plastic fasteners. Clamp trim piece in position. Set aside to cure.
Passenger Sub Frame
Bolt seat lock onto new carbon sub frame using stock bolts and M6 nylocs supplied.
Remove two rubber stops from original sub frame and mount in new carbon unit.
Battery Tray
Take stock rubber strap used to secure ECU. Feed one end through hole in center of flat, rear portion of new battery tray. When loop shows through the underside slide pin through the loop to retain strap. Pull strap tight through top.
Riders Seat
Remove small piece of foam on underside of rider’s seat pan.
ECU
Cut the black wire with brown trace that is located in pin number 8 of the grey ECU connector. Cutting this wire has no effect on the performance of the bike and prevents the FI warning light due to removal of the exhaust valve
Stage Three Assembly
Rear Hugger and Gas Tank
Replace hugger, routing the brake line along the inside of the swing arm. Secure the line with a tie wrap. Drop the gas tank and replace front mounting screws.
Battery Tray
1. Push new battery tray down between frame rails, ensure wiring harness remains along the inside of the left hand frame rail. When close to the front slip the tip cut out switch over mounts at front of the tray.
2. Slide two relays over slots in each side of the step in the tray. Ensure air pressure sensor (the one with the long tube sticking out) remains hanging over the frame rail.
3. Push the tray down into position feeding main ECU wiring through cut out in rear of left side of tray. Ensure start relay cables are fed under the tray and under the top frame mount. Push start relay onto bracket at rear of the tray.
4. Locate the front of the battery tray with the M6 x 10 hex head bolt supplied into the lower, central fixing – only finger tight at this time.
5. Fix four M6 x 10 countersunk bolts in top of battery tray. When all four are located, tighten together with front mounting bolt.
6. Replace stock rubber mat under battery and drop into position.
7. Place air pressure sensor with tube facing down in recess at rear of battery and secure with a tie wrap.
8. Connect positive terminal.
9. Feed rubber loop between ECU connectors. Pull loop over ECU and attach to T – bolt above air pressure sensor.
Passenger Sub Frame and Mufflers
1. Push S – pipe over headers and push forward, fully home. Replace stock lower mounting bolt and use the nut you saved from the muffler hanger. Only tighten finger tight at this stage.
2. With a dab of grease, retain an M8 plain washer on the outside of each rear sub frame mounting hole.
3. Offer up the new, carbon passenger sub frame and push two M8 x 25 hex head bolts through the front mounting holes and through the mounting holes in the rear of the battery tray. Repeat with rear mounting bolts. Mount plain washer and M8 nylocs, tighten loosely.
4. Push the mufflers over the tail pipe. Align the slash cuts so the apex is vertical and they match each other. A useful trick here is to use a flat sheet and press it up against the muffler ends to align them.
5. Grab the two muffler hangers – note that the mounting flange is offset to one side. Position the two hangers side by side so that the short offset of each hanger is to the inside and the flange is orientated straight up. Insert the license plate mount on the inside, bottom of each hanger and slide together over the mufflers. Push down the mufflers so that the flanges line up with and are to the inside of the mounts in the sub frame.
6. Push an M8 x 15 hex head mounting bolt through from the outside of the sub frame mounts, engage holes in both sides the muffler hanger and screw on a plain washer and M8 nyloc from the middle only loosely at this stage. Repeat for the other side.
7. Check muffler hangers are exactly side-by-side – they should be touching each other in the center! Check the license bracket is horizontal and then tighten the mounting bolts, pushing the two mufflers together as you tighten the bolts.
8. Stand back and review the alignment of the mufflers and when satisfied that all is straight tighten the following:
- muffler to tail pipe clamps
- lower S – pipe mounting bolt
- S – pipe to header clamp
- 4 x passenger sub frame mounting bolts
- replace belly pan mounting bolt
- riders footrest
9. Feed tail light cable up between mufflers and attach brake/tail light LED via connectors to stock wiring harness. Colour coding for the LED is:
| Stock |
New |
| Black/white tracer |
Black |
| White/black tracer |
Green |
| Brown or grey |
Red |
10. Connect negative battery terminal.
11. Replace tail unit, rider’s seat. Before replacing passenger seat be sure to reconnect the seat lock cable.
12. Finally, go back over every fastner and fitting and check it for tightness.
Now, stand back and take a moment to admire the results of all your hard work. All that remains is to fire her up and go for a spin.
After running the bike for approximately 100 miles go over
all fasteners and check for tightness
.
Should you have any questions concerning the fitting of your exhaust
please do not hesitate to call me for advice on 818 781 8123
.
Ride safe,
Paul Taylor
WARRANTY AND LIMITATIONS
Regarding products sold by TaylorMade Racing Inc. (TaylorMade)
e.g., exhaust systems, composites, billet parts, etc., TaylorMade
warrants these products against defects arising out of failure
due to material and/or workmanship for a period of 1 year from
the date of purchase regardless of actual "in service"
date. This warranty is limited to the repair or replacement of
the item solely at the discretion of TaylorMade. Such repair or
replacement will be determined based solely on TaylorMade’s
Evaluation of the item’s intended and actual use.
Regarding products purchased from TaylorMade but not manufactured
by TaylorMade, NO WARRANTIES WHATSOEVER are granted or implied.
Any and all claims regarding items sold by TaylorMade but not
manufactured by TaylorMade are to be referred to and disposed
of by the actual manufacturer. Claims regarding these items may
be administered by TaylorMade or referred to the actual manufacturer
at TaylorMade’s discretion.
EXCLUSIONS
This warranty does not cover finished such as plating and paint
ant their failure due to discoloration from heat or weathering
or abuse. Nor does it cover any failure due to damage arising
out of improper installation, crash damage or incompatibility
with other components, In any event, TaylorMade accepts no liability
for any damage to vehicles or persons arising out of the use and/or
abuse of a vehicle equipped with TaylorMade components, nor will
TalorMade accept liability for damage to injury or persons from
the use or abuse of the product itself, whether direct or indirect,
voluntary or involuntary. TaylorMade will not be responsible for
any dispositions made by dealers or distributors of products.
TaylorMade will not be responsible for any labor charges incurred
by the customer for the installation or removal of the TaylorMade
component or changes arising out of the collateral damage to the
vehicle or persons while installing, removing, or using any item
purchased from or supplied by TaylorMade whether manufactured
by TaylorMade or not.
RETURN POLICY
TaylorMade will not be responsible for any shipping charges by
the purchaser in returning the part to TaylorMade for evaluation.
A return authorization number and a copy of the purchaser’s
invoice or receipt must accompany all returns. Parts returned
without authorization may be refused.
DISCLAIMER
TAYLORMADE EXHAUST SYSTEMS, ENGINE PARTS, OR ANY PART WHICH MAY
EFFECT EMISSION REGUALTION COMPLIANCE ARE FOR OFF HIGHWAY USE
ONLY AND ARE NOT FOR SALE OR USE ON CALIFORNIA POLLUTION CONTROLLED
VEHICLES OR IN OTHER STATES WHERE POLLUTION CONTROL LAWS APPLY.
SUITABILITY OF APPLICATION IS THE SOLE RESPONSIBILITY OF THE PURCHASER
