YAMAHA XSR900 / MT09 FULL STAINLESS EXHAUST SYSTEM (2022+ XSR, 2021+ MT)

INSTALL INSTRUCTIONS:

STEP 1: UNINSTALL YOUR STOCK SYSTEM

1. Cut the zip tie at the coolant hose join

2. Remove the o2 sensor with a 17mm spanner

3. Remove radiator mount between engine and radiator via the bolt into the motor and then leverage the radiator forward to give yourself more space to work with. You can then remove the two allen key bolts at the top of the radiator to give much more space to work with.

4. Ideally using a 12mm socket on a socket joint with 3" extender bar, remove the header flange nuts holding the motor to the exhaust headers.

5. Once your headers are free and your o2 sensor is out of the way, remove the two 12mm lower muffler support bolts (one on each side below the footpegs) and wiggle the exhaust down and out.

6. Dab some grease onto the exhaust gaskets which may have already fallen out to stick them into the motor before attempting to fit the new headers.

Note: You can replace your exhaust gaskets cheaply, but as these are torqued very lightly from factory and it's a new bike, it is fine to reuse and simply add a few NM of torque to the factory spec to crush the gasket slightly to seal.

STEP 2: INSTALLING YOUR KELPI SYSTEM

1. Assemble the individual headers to merge collector using the spring positions as a guide until you have an aligned set of headers, then spring them up.

2. Wiggle your headers on and get the plate over the header flanges with your flange nuts on a couple of turns, watching to ensure you're getting the headers cleanly into the motor exhaust ports as you do. This can take some time and is often best done by getting the each cylinder's flange plate on with header flange nuts tightened just enough to have their positions correctly in the exhaust ports. As long as none of the nuts are tightened too much, the other headers will be able to be wiggled into place and the link pipe fitment becomes simple.

3. Before you've tightened the header flange nuts, install the link pipe (with high flow cat) by inserting it onto the merge, rotating it clockwise so that the bracket fits in.

behind it's mounting point. Use existing bolt plus supplied m8 nut to fasten the link pipe into place. Ideally you want this sitting as far forward on it's mounting slot as possible, and this is why it's important to leave the header flange nuts slightly loose until you've got the stock exhaust mounting bolt into the link hanger slot with our supplied nut torqued to standard M8 specs in Step 6.

4. Attach two springs between the merge collector and the link pipe, and then connect three springs from the flange plates that sit against the motor to each header pipe. There are multiple holes cut into the plates to allow different spots, but a spring puller tool or hook tool is highly recommended as there isn't a great deal of space to work with.

5. Torque down your header flange nuts to seal the headers to the motor.

6. Before fitting the muffler it can be helpful to remove the footpeg assembly to more easily fasten up bolts. Keep it raised up out of the way with a zip tie.

7. Slot the muffler onto the link pipe, with the dB killer in our out depending on your preference. Seal it in place with two springs from the muffler to the exhaust system.

8. There's a 14mm bolt on a frame mounting point that's under the footpeg position and to the left of the link pipe mounting point. Remove the bolt and mount the black powdercoated bracket into position so that it aligns with the muffler and ensures clearance from the swingarm. For Flanker systems, it's important to position it up and refit the footpeg setup to check clearance from the rear brake. For positioning, you're wanting to sit the muffler roughly 5-15mm off of the swingarm with any amount of clearance from the brake pivot's full travel, as once you're seated the system will drop lower.

9. Once you've set your muffler position, torque down the muffler hanger bolt and then the 14mm bolt on the frame mounting side. This can be adjusted down the track by loosening your muffler hanger bolt and shifting the muffler position before tightening the bolt on the muffler slot and fixing it's new position.

10. Rotate your o2 sensor counter clockwise 6-7 full rotations and then screw it into the new exhaust system o2 bung - this will ensure it's not twisted. Check torque spec for the o2 sensor as it does not require a great deal of force and can be damaged easily.

11. Nip up the 02 sensor with a spanner and add a fresh zip tie to keep it in place on the radiator hose.

PERFORMANCE NOTES

Your systems come with baffles, which bring the volume down considerably, and work nicely with the stock tune. Using them is purely up to the owner's preference however, we highly recommended putting them in when going in for roadworthy inspections. If you’re wanting the best top end performance, running no baffle and having the bike dynotuned to suit is the best way to achieve that, but the baffled system sounds great and feels both smooth and responsive on the stock tune.

NOTE: Do not turn your motorcycle on or start the bike until you have reinstalled the o2 sensor. Failure to do this will result in a ‘check engine’ code being thrown which will cost $50 for yamaha to reset the code if you don’t have your own OBDLink scan tool and know-how.

YOU WILL NEED

- Blade or side cutters

- Socket joint

- 3” extender bar

- 12mm socket

- 14mm socket

- 12mm spanner

- 13mm spanner

- 14mm spanner

- 17mm spanner

- Set of Allen keys

- 1 zip tie

- Grease

- A mate: you can do this yourself but it’s much easier with someone to help out

ANY QUESTIONS?

Feel free to reach out via email kelpicustommoto@gmail.com or give Jock a call on

0488080959