Yoshimura 19701BD520 Bedienungsanleitung

19701BD520 (SS/CF)

Husqvarna

701 Enduro

Supermoto

2016~2022

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

NOTE: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM, WHICH INCLUDES THE CARBURETORS OF ANY VEHICLE.

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 motorcycle cool down before beginning installation. Always wear hand and

eye protection and take precautionary measures to avoid injury.

RACE SERIES

Qualified Manufacturer Declared “Modified Part ”

Stainless Steel R-77 Slip-On

FOR CLOSED COURSE COMPETITION ONLY; NOT INTENDED FOR STREET USE

Race Series systems are:

• NOT CARB/EPA tail-pipe emissions compliant.

• NOT street legal.

• For “Closed Course Competition” use only.

KTM

690 Enduro R

2014~2018

Assembly Diagram

** Not Shown on diagram.

No. Item Description Qty.

1 19701-435 Yoshimura Tailpipe 1

2 19701BD520-LMA Yoshimura Muffler Assembly 1

3 20062 Exhaust Clamp 1

4 M8X50H 8mm x 50mm Flanged Hex Head Bolt 1

5 RACE-SPS-1 Medium Exhaust Spring 2

6 8MMNUT 8mm Flange Nut 1

** SA-16-K Spark Arrester Kit 1

** ST-200 Spring Puller Tool 1

** 17029 Sticker Sheet 1

1. Remove rider seat.

2. For Husqvarna 701, follow installation steps “a”.

For KTM 690, follow installation steps “b”.

2a. Remove the three header heatshield bolts and

remove heatshield.

Note: There are two tabs on the heatshield with

rubber sleeves that clip into the left side

panel.

2b. Remove the two muffler heatshield bolts and

remove heatshield. Remove fuel filler cap and

disconnect fuel breather hose. Remove the four

bolts and three screws securing the upper rear

fender.

Note: The three screws are located underneath

the license plate holder.

3a. Remove left side panel by removing the bolt

on the top rear by the rear fender. Carefully pull

side panel outward and slide forward to remove.

3b. Slide upper rear fender cover forward to clear

fuel breather nipple and remove.

4. Loosen muffler exhaust clamp and while

securely supporting the stock muffler, remove

muffler mount bolt and carefully remove the

stock muffler assembly.

Note: The exhaust gasket will not be re-used

with the Yoshimura slip-on system.

Removal

CAUTION: Exhaust system can be extremely hot.

Let motorcycle cool down before

beginning installation. Always wear

hand and eye protection and take

precautionary measures to avoid

injury.

WARNING: Always properly support vehicle with

a stand and/or lift when servicing or

performing any work. Unstable

vehicles may present dangerous

conditions and may cause property

damage and/or personal injury.

NOTE: Read through all instructions before

beginning installation. 2. Install (No. 1) 19701-435, tailpipe outlet into

muffler inlet.

3. Install muffler/tailpipe assembly over the stock

header outlet while simultaneously aligning

muffler bracket to muffler mount. Secure using

(No. 4) M8X50H, 8mm bolt and (No. 6)

8MMNUT, 8mm flange nut. Torque to factory

specification.

Note : The two stock muffler mount collars must

be re-used.

Note : Muffler mount installs between the

muffler bracket.

4. Torque (No. 3) 20062, exhaust clamp to 8.5 Nm

(6 ft-lb, 0.86 kg-m).

5. Install (No. 5) RACE-SPS-1, medium exhaust

springs between muffler and tailpipe using the

ST-200, spring puller tool supplied in the kit.

6a. Re-install left side panel.

6b. Re-install upper rear fender and fuel filler cap.

7a. Re-install header heatshield. Check to make

sure heatshield tabs are secured in the side

panel slots.

7b. The stock muffler heatshield will not be re-used.

8. Re-install rider seat.

Muffler Mount

Installation

1. Slide (No. 3) 20062, exhaust clamp over (No. 1)

19701-435, tailpipe inlet. Do not torque at this

time.

Works Finish

Care & Maintenance

Before starting vehicle, clean pipe thoroughly using

a soft cloth and rubbing alcohol to remove any oil

and finger prints.

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.

9. Before starting 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 problem still persists, please call

Yoshimura Tech Department at (800) 634-9166

/ in CA (909) 628-4722.

10. 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 motorcycle, it is normal for

new exhaust system and muffler to emit

smoke until oil residue burns off.

Dear Yoshimura Customer,

Congratulations and thank you for purchasing a Yoshimura Exhaust System. Over six decades of experience in research

and development, state of the art machinery, materials and craftsmanship of the highest quality all come together in a

product of exceptional quality and performance—in other words, this is the best thing you can put on your bike.

We strive to provide you with a product perfect in fit and finish. However, if you have any problems, please give us a

call. We have found that most fitment issues can be easily resolved by a conversation with one of our knowledgeable

and friendly staff. If the issue cannot be resolved this way, our warranty evaluation program may be the answer. Please

take a moment to review our recommendations for the care of your exhaust and our warranty information.

PLEASE NOTE: If you have any doubts about your exhaust: DO NOT START THE MOTORCYCLE! ONCE AN EXHAUST HAS

BEEN USED OR MODIFIED, IT CANNOT BE RETURNED FOR CREDIT OR EXCHANGE.

EXHAUST SYSTEM MAINTENANCE

Yoshimura Exhaust Systems require very little care and maintenance; here are a few tips:

1. Use mild car/motorcycle soap to clean the exhaust system—do not use any abrasives or degreasers.

2. Clean your exhaust with metal/stainless polish every 1-2 months to retain the luster and remove dirt and grime.

(DO NOT USE POLISH ON “WORKS FINISH” SYSTEMS)

3. Avoid contaminating exhaust surfaces when hot.

4. 4.Your exhaust system will change color (blue, magenta, purple, and/or gold) due to heat; this is normal.

5. Keep all clamps, bolts and other fasteners tight as exhaust systems are susceptible to vibration damage.

6. If you ride in coastal regions or areas that use salt to control ice and snow, wipe the exhaust down after it cools to

remove any possible salt residue, which can result in rusting.

7. If you are storing your motorcycle for the season, wipe the exhaust system down with rubbing alcohol before

storage.

8. Head pipes glowing (visible in normal light) may indicate an excessively lean condition that must be corrected.

CARBON FIBER:

Carbon fiber equipped exhaust components require special attention. The following addresses wear issues directly

related to carbon fiber:

1. Keep all clamps, bolts and other fasteners tight. Carbon Fiber is very susceptible to vibration damage.

2. Keep all chemicals and solvents away from the carbon fiber, as they will damage the finish.

3. High temperatures will cause the resin in the carbon fiber to break down. Visual signs such as an amber hue in the

resin may be early signs of heat damage to carbon fiber.

4. Upon seeing amber colored resin, discontinue use. The exhaust system needs to be inspected by a representative

from Yoshimura, for repack, and/or repair. Continued use will cause component failure.

STAINLESS STEEL:

Stainless Steel is not rust proof but is less prone to rusting, staining and pitting; but it is prone to oxidation like all

metals.

WORKS FINISH:

1. Works Finish exhaust systems should never be cleaned with abrasives or polishes.

2. Yoshimura recommends using “Bar Keepers Friend” cleaner to remove minor stains.

3. 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.

RE-PACKING TIPS

To maintain maximum sound and engine performance the muffler packing will need to be replaced at some time during

the muffler’s life. Yoshimura recommends repacking your muffler at least once a year.

Failure to maintain the muffler packing may cause damage to the muffler and/or void the warranty. Regularly inspect

the muffler body for discoloration, cracks, rattling, or other signs of wear caused by depleted muffler packing. If muffler

packing is determined to be depleted or worn, a Yoshimura muffler re-pack kit is highly recommended to restore the

muffler to optimum maximum performance.

Yoshimura offers a 3-5 day turn around (plus transit time) to inspect and refurbish used and damaged mufflers.

For more information on muffler repacking please visit our website at: https://www.yoshimura-rd.com/pages/repack-

and-insert-chart

***PRO TIP*** Before you install your new muffler for the first-time log the weight in your Owner’s or Service manual

along with the current hours or mileage on your vehicle. When you are performing periodic maintenance on your

vehicle (like a tire change, or an oil change) you can remove your Yoshimura muffler from the vehicle and weigh it again.

Over time, the packing material inside your muffler will burn off with use, and the muffler will need to be repacked.

When the weight loses approximately 100 grams of the original weight, you should consider getting your Yoshimura

muffler repacked. You can order repacking kit or the parts to repack the muffler from the Yoshimura website, or

your local dealer. You can also contact the Yoshimura sales office and arrange to send in your muffler for the repacking

service too.

IMPORTANT TECHNICAL NOTE

Yoshimura recommends on all race exhaust systems, that all spring joints be safety wired. Recommended wire type

304/316 stainless steel with a .032” diameter should be used.

YOSHIMURA EXHAUST LIMITED WARRANTY

All Yoshimura R&D of America, Inc., exhaust systems carry a one-year limited warranty against defects in workmanship

and/or materials.

WHO IS COVERED?

This warranty is provided to the original purchaser of the exhaust system.

WHAT VOIDS THE WARRANTY?

1. Abuse, misuse, improper installation and/or modifications

2. Custom applications

3. No proof of purchase at the time of warranty. Claimant must provide proof of purchase (original receipt or invoice)

and a warranty authorization number (RMA) obtained from Yoshimura.

4. Finishes such as plating or painted surfaces with discoloration or rust due to inclement weather conditions, exposure

to salt, exposure to chemicals, or lack of maintenance by the customer are not covered.

5. International grey-market product purchased through a dealer/distributor not authorized for your country will not

be supported by this warranty.

EXTENT OF WARRANTY:

Any defective exhaust system properly returned to Yoshimura will be repaired or replaced by Yoshimura. Yoshimura is

not responsible for any other expense incurred by the customer under the terms of this limited warranty, nor is

Yoshimura responsible for any damages either consequential, incidental, special, contingent or otherwise; or expenses

or injury arising directly or indirectly from the use of the exhaust system. Any exhaust system returned to Yoshimura

must be sent at the customers expense along with the proof of purchase and warranty authorization (RMA). Yoshimura

reserves the right to determine whether the terms of the warranty, set out above, have been properly followed. In the

event that the terms are not followed this warranty is void. Yoshimura is the sole determiner of abuse, misuse,

installation errors and modifications—should any of these be found, this warranty is void. The duration of any and all

implied warranties are limited to the duration of the express warranty. All incidental or consequential damages are

hereby excluded. The warranty gives you specific legal rights and you may have other rights, which vary from state to

state. Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how

long an implied warranty lasts, so the above limitations and exclusions may not apply to you.

If you have a fitment or other problem, or are missing a part, please double-check this trouble shooting guide first:

1. Reference your instruction sheet and double-check all drawings and instructions

2. Make sure muffler clamps are installed correctly (refer to instructions diagram). On many models, there is a right

and wrong way to install. Also verify part numbers on headers and tail pipe.

3. Always make sure to install spring-mounted manifolds and flanges on cylinder head prior to installing headers.

4. Always take time to examine problems in detail.

5. When all else fails, call our technical support line at (909) 628-4722. The technical line is open 9:00am – 4:30pm

Monday through Friday, Pacific Time. Please have the following information handy: Year/Make/Model of

motorcycle, date of purchase, place of purchase, batch dates and part numbers (found on header and tail-pipe

components).

6. Also, feel free to ask through online e-mail at sales@yoshimura-rd.com, or fax your question/problems to (909) 591-

2198.

To obtain technical information directly from Yoshimura, call (909) 628-4722.

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