How to Install the RS-2 Slip-On on a Suzuki LTZ400
By Yoshimura R&D of America, Inc. | Published: 2026-10-28
Category: How-to Guides
Step-by-step guide to installing the Yoshimura RS-2 slip-on exhaust on a Suzuki LTZ400, with torque specs, alignment tips, and common mistakes to avoid.
Quick Answer
Install the Yoshimura RS-2 slip-on on your Suzuki LTZ400 by removing the stock muffler, fitting the new system with new gaskets, and torquing all fasteners to spec—expect about an hour of work with basic hand tools.
Before You Start: What You Need and What to Watch For
The RS-2 is a slip-on exhaust, meaning it replaces only the muffler section, not the full header pipe. This makes installation straightforward, but you still need to handle the stock mounting points and gaskets carefully to avoid leaks or vibration issues.
Since the RS-2 uses a larger core and increased packing volume, it’s quieter than a straight-through design while still improving power delivery. That larger core also means the muffler body is slightly bigger, so double-check clearance around the rear shock and swingarm before tightening everything down.
Step-by-Step Installation
- Prep the Quad: Park the LTZ400 on a level surface and let the exhaust cool completely. Disconnect the battery negative cable to avoid accidental electrical shorts. Loosen the stock muffler’s mounting bolts and spring hooks with a socket and pliers. Check that you have all the included hardware and the new gasket before you start.
- Remove the Stock Muffler: Slide the stock muffler off the header pipe. If it’s stuck, gently twist it back and forth while pulling—don’t pry against the header. Remove the old gasket from the header pipe and discard it. Inspect the header pipe for dents or rust; if it’s damaged, the new slip-on won’t seal properly.
- Fit the RS-2 Muffler: Slide the RS-2’s inlet over the header pipe, aligning the mounting bracket with the frame tabs. The diamond-shaped sleeve should sit so the Yoshimura logo is upright. Loosely install the mounting bolts and spring hooks—don’t tighten yet. Verify the muffler doesn’t touch the swingarm or shock; adjust the bracket position if needed.
- Torque and Test: Tighten the mounting bolts to the torque spec in the instruction manual (typically 25-30 ft-lbs), then attach the springs. Reconnect the battery, start the engine, and check for exhaust leaks around the joint. Let it idle for a few minutes and listen for rattles. After a short ride, re-check the bolts—heat cycles can loosen them.
The Exhaust That Makes It Worth It
- SUZUKI/KAWASAKI LTZ400 03-14 RS-2 Stainless Slip-On Exhaust, w/ Aluminum Muffler: The RS-2 evolved from the original TRC design and features a larger core with increased muffler packing volume for quieter operation. That means you get a performance bump without the harsh, high-pitched drone that some aftermarket exhausts produce—good for trail riding and longer trips.
SUZUKI/KAWASAKI LTZ400 03-14 RS-2 Stainless Slip-On Exhaust, w/ Aluminum Muffler
