2006-2007 Suzuki GSXR600/750
I n s ta l l a t i o n I n s t r u c t i o n s
Parts List Ignition module Velcro
Installation Guide Alcohol Swab Strip
You can also download the
Power Commander software and latest maps from our web site at: www.powercommander.com
This module is intended to be used in conjunction with Power Commander 316-410
The ignition MUST be turned OFF before installation!
Power Commander may need to be updated.
(see included instructions)
Before this module can be used the
PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION
Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV 89081 (800) 992-4993

www.powercommander.com

06-07 Suzuki GSXR600/750 - PCIII USB - 1
Remove the main seat. Lift the front of the fuel tank up. Remove the air box. Place the ignition module next to the left hand side and go towards the front of the bike.

Fig. A

PCIII and route the harness down the

PCIII harness

Route the PCIII to the left side of the interfere with the throttle linkage (Fig. A).
throttle bodies making sure it does not

Fig. B

Disconnect the stock wiring harness from the coil sticks (Fig. B).

Unplug from

coil sticks
Plug the ignition module connectors coil sticks (Fig. C).
in-line of the stock wiring harness and

Fig. C

Ignition module colors: ORANGE - Cylinder #1 YELLOW - Cylinder #2 GREEN - Cylinder #3 BLUE - Cylinder #4
06-07 Suzuki GSXR600/750 - PCIII USB - 2

Unplug crank

connector

Fig. D

Locate the crank pickup coil connector (Fig. D). WHITE 2 pin connector with a BLACK and a GREEN wire. This connector is a

Ground wire from PCIII

Stock connectors

Fig. E

Connect the WHITE connectors from the ignition module in-line of the (Fig. E). stock crank pickup sensor connectors

Module connectors

Ground wire
Attach the ground wire from the ignibattery (Fig. F).
tion module to the negative side of the
06-07 Suzuki GSXR600/750 - PCIII USB - 3
Install the ignition module in the tail section of the bike.
to the top of the PCIII if necessary by using the supplied velcro. 11

It can be attached

Plug the white 10 pin connector from port of the PCIII. If you are using a

Fig. G

the ignition module into the expansion quickshifter then unplug the quickthe expansion port of the igntion module harness.
shifter from the PCIII and connect to

Quickshifter connection

Reinstall the air box and fuel tank.
06-07 Suzuki GSXR600/750 - PCIII USB - 4

Installation Instructions
1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on a centerstand or ideally a service lift. 2. Remove right side lower fairing bolts and pull lower fairing out from push fit connector. 7. Remove lower rear set bracket bolt and install new 8x40mm socket head cap screw provided.

GSX-R600/750

2006-07 Suzuki

V.A.L.E.

V a r i a b l e

A x i s

L o c k i n g

E x h a u s t

V.A.L.E. Slip-on Exhaust System with M-2H Canister Part # 005-1470406V2 / 005-1470407V2 / 005-1470408V2
3. Loosen muffler clamp at headpipe joint
8. Use the threaded portion of this bolt sticking out the inside of the bracket to mount the supplied muffler mounting bracket. Use the 8mm nut to secure in the correct location after the muffler is positioned.
4. Remove the 3 muffler mounting bolts
9. Use the 6x14mm Socket Head Cap Screws and split lock washers to loosely join the s-bend to muffler. Do night tighten yet. Muffler Inlet

X-Lite Ring

Parts List

Qty. Description

1 Suzuki GSX-R600/750 Muffler Canister M-2H 1 Muffler Clamp 1 Suzuki GSX-R600/750 New V.2 S-tube 1 HARDWARE KIT 1 X-Lite V.A.L.E. Retaining Ring 1 Barrel Clamp 1 Mounting Bracket 1 8x40mm Socket Head Cap Screw 1 8x20mm Flange Bolt 2 8mm Flat Washer 2 8mm Lock Nut 1 5mm Long Handle Ball end hex key 1 Permatex Ultra Black Gasket Maker 4 6x14mm Socket Head Cap Screw 4 M6 Split Lock Washer

Slip Tube

Part Number
Varies Varies 005-14704SV2 005-147-3 005-7-2-2 005-27-63MSH 005-147-19-3 005-SH840 005-FB820 005-WF8 005-NN8 005-9-18610 031-P22072 005-SH614 005-WL6 The third muffler mounting bolt is located behind the lower fairing on the left side of the bike.

V.A.L.E. Assembly Detail

5. Remove OEM muffler assembly. 10. Slide the barrel clamp over s-bend and join to headpipe. Do not tighten yet. Use High Temp Silicone.

Use High Temp Silicone

IMPORTANT - PLEASE READ CAREFULLY We recommend that this performance part be installed by a qualified motorcycle technician. If you have any doubts as to your ability to install this performance part, please consult with your local motorcycle dealer. Read all instructions first before starting installation. Make sure the motorcycle and exhaust system are completely cool before starting the installation. Also, make sure the bike is secure on a centerstand or ideally a service lift during installation. Be sure to save all stock components for possible use later.
6. Reverse the rear linkage bolt by removing it and inserting it from the exhaust side of the bike for proper clearance between the bolt and muffler.

(Continued on page 2)

15. Check for clearance on the frame, linkage, and swingarm.

(Continued from page 1)

16. Re-install side panel. 17. Double check your work to ensure everything is tight and properly installed. 18. Before you run the bike, clean off all fingerprints and dirt, as any oily residue will etch the metal and become somewhat permanent when the system gets hot. Run the bike and enjoy. It is normal for some white smoke to appear the first time you start the bike. This is packing/manufacturing oil from inside the pipe burning off. Check for gaps or leaks. If you find a leak, a little high temperature silicon sealant should fix it. After 50 to 100 miles, recheck all fasteners for tightness.

11. Slide the rubber lined muffler clamp over the muffler and join the muffler clamp to the muffler bracket. The muffler clamp goes inside of the bracket as shown. Use the supplied bolt and washer.
12. Tighten muffler bracket (muffler will sit at an angle, this is normal).

Care & Cleaning

Care & Cleaning Keep system free of dirt and moisture. Store in a cool, dry place. Make sure vehicle is completely cool before maintenance. Stainless Header System: Polished stainless steel pipes will turn a light golden hue after a few heat cycles, this is a normal characteristic of high quality stainless steel. Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth. Titanium Header System: Polished titanium pipes will experience color shift ranging from deep blue/purple through amber after a few heat cycles. This is a normal characteristic of high quality titanium. Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth. Polished Aluminum Canisters: Use an aluminum or mag wheel polish to restore the bright finish to factory spec. Brushed Aluminum Canisters: Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth. Carbon Fiber Canisters: Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth. Always make sure the fiberglass packing inside is in good condition and not burned out, as exhaust heat inside an empty canister will deteriorate the carbon fiber sleeve. TBR sells repack kits (Road - #005-10038, Offroad - #005-10038MX) that include everything you need to easily do it yourself. Titanium Mufflers: For cleaning use a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth. Always make sure the fiberglass packing inside is in good condition and not burned out, as exhaust heat inside an empty canister will deteriorate the carbon fiber sleeve. TBR sells repack kits (Road - #005-10038, Offroad - #005-10038MX) that include everything you need to easily do it yourself. Repack all road canisters every 3,000 miles. Part #005-10038 Repack all offroad canisters after every 10 hours of use. Part #005-10038MX NEVER dyno test your bike with carbon fiber or titanium canisters installed - the intense heat and lack of cooling air can quickly burn through the canister material. Two Brothers Racing does not provide a warranty for burned canisters.

13. Tighten the 4 6x14mm socket head cap screws or V.A.L.E. assembly.
14. Tighten barrel clamp.

005-1470406V2

005-1470407V2

005-1470408V2

1 Suzuki GSX-R600/750 AL Muffler Canister M-2H 1 Suzuki GSX-R600/750 New V.2 S-tube 1 Muffler Clamp 1 HARDWARE KIT 1 X-Lite V.A.L.E. Retaining Ring 1 Barrel Clamp 1 Mounting Bracket 1 8x40mm Socket Head Cap Screw 1 8x20mm Flange Bolt 2 8mm Flat Washer 2 8mm Lock Nut 5mm Long Handle Ball end hex key Permatex Ultra Black Gasket Maker 4 6x14mm Socket Head Cap Screw 4 M6 Split Lock Washer
005-147-206 005-14704SV2 005-2C 005-147-3 005-7-2-2 005-27-63MSH 005-147-19-3 005-SH840 005-FB820 005-WF8 005-NN8 005-9-18610 031-P22072 005-SH614 005-WL6
1 Suzuki GSX-R600/750 CF Muffler Canister M-2H 1 Suzuki GSX-R600/750 New V.2 S-tube 1 Muffler Clamp 1 HARDWARE KIT 1 X-Lite V.A.L.E. Retaining Ring 1 Barrel Clamp 1 Mounting Bracket 1 8x40mm Socket Head Cap Screw 1 8x20mm Flange Bolt 2 8mm Flat Washer 2 8mm Lock Nut 5mm Long Handle Ball end hex key Permatex Ultra Black Gasket Maker 4 6x14mm Socket Head Cap Screw 4 M6 Split Lock Washer
005-147-207 005-14704SV2 005-2C1 005-147-3 005-7-2-2 005-27-63MSH 005-147-19-3 005-SH840 005-FB820 005-WF8 005-NN8 005-9-18610 031-P22072 005-SH614 005-WL6
1 Suzuki GSX-R600/750 Ti Muffler Canister M-2H 1 Suzuki GSX-R600/750 New V.2 S-tube 1 Muffler Clamp 1 HARDWARE KIT 1 X-Lite V.A.L.E. Retaining Ring 1 Barrel Clamp 1 Mounting Bracket 1 8x40mm Socket Head Cap Screw 1 8x20mm Flange Bolt 2 8mm Flat Washer 2 8mm Lock Nut 5mm Long Handle Ball end hex key Permatex Ultra Black Gasket Maker 4 6x14mm Socket Head Cap Screw 4 M6 Split Lock Washer
005-147-208 005-14704SV2 005-2C2 005-147-3 005-7-2-2 005-27-63MSH 005-147-19-3 005-SH840 005-FB820 005-WF8 005-NN8 005-9-18610 031-P22072 005-SH614 005-WL6