Your Undertail Exhaust kit should include the following parts:

1) Removing The Stock Parts Before the Installation of Undertail Exhaust Kit1 – Remove the stock mud flap/license plate holder2 – Remove Stock Exhaust Canister3 – Remove Seats4 – Remove Stock Tail Section5 – Remove the Metal heat shield

CAREFULLY READ ALL INSTRUCTIONS BEFORE BEGINNING THE INSTALLATION PROCESS! AS WITH ANY PERFORMANCE MODIFICATION,YOU SHOULD ALWAYS CHECK YOUR WARRANTY BEFORE MAKING ANYMODIFICATIONS TO THE EXHAUST CANISTER OR EMISSIONS DEVICES.

HOTBODIES RACING WILL NOT BE HELD RESPONSIBLE FOR ANY MISUSE OR DAMAGESCAUSED BY THE INSTALLATION OF THIS PRODUCT, NOR WILL WE REPLACE ANY STOCKPARTS TO YOUR MOTORCYCLE.

HOTBODIES RACING RECOMMENDS THAT YOU HAVE A PROFESSIONAL MECHANICPERFORM THIS INSTALLATION, THIS PRODUCT WILL REQUIRE RE-MAPPING OF THEFUEL INJECTION TO GET ITS FULL POTENTIAL, WE SUGGEST USING A “POWER COMMANDER III” AND HAVING IT PROFESSIONALLY TUNED USING A DYNOMETERAND AN EXHAUST GAS ANALYZER.

IF YOU CHOOSE TO “DO-IT-YOURSELF”, WHICH WE DON’T RECOMMEND, ALWAYSTAKE APPROPRIATE SAFETY MEASURES WHEN INSTALLING THIS PRODUCT, SUCH ASSAFETY GOGGLES AND LEATHER GLOVES.

1 – Exhaust Canister1 – Undertail w/ heat shielding 2 – 13mm Lock nuts

3 – 10” Section of Heat Shielding 2 – Pop Rivets (Not shown) 2 – L Shape license plate brackets

1 – Doubled over peice of Heat Shield4 – Fiberglass Washers

READ CAREFULLY BEFORE INSTALLATION! This undertail like all undertails has been designed for off road racing use only, and has not been presented for D.O.T. certification! Hotbodies Racing Inc., our distributors, and our dealers will NOT be responsible for the use or misuse of this product.

Always check with your local Department of Motor Vehicles before modifying any aspect of your motorcycle.

ZX6R/RR Undertail Exhaust(2005-06)

3) Relocate the ECU as shown. Remove the rubber case andfold back on top of the battery. The seat will hold firmlyin place and out of harms way.

5) Place heat shield on the subframe to keep heat awayfrom the ECU and battery as shown.

5) Using a zip tie relocate the fuses to the left side of thesubframe.

2) Remove the glove box as shown, it has 4 bolts, 2 at thetop and 2 at the bottom. YOU MUST REMOVE THEGLOVE BOX TO ALLOW FOR AIR CIRCULATION.

4) Remove the plastic heat shield on the right side.

7) Route the stock cables for the exhaust valve as shown.

8) Mount the exhaust canister as shown, use stock exhaustclamp. Exhaust clamp should be facing down on theright side so it does not contact the undertail.

9) Using the 2 supplied lock nuts and the stock bolts, attachthe canister to the subframe in the two stock locations.Place the fiberglass washers in between the exhaust andthe mounting tabs as shown in the 2nd photo.

10) Trim the small 1/8” lip off the inside of the left side ofthe tail section using a dremel tool as shown. You maywant to use masking tape to protect the outside paint-ed surface, be sure to sand from the inside.

11) Place the undertail into position in the stock tail sec-tion, measure 3.5” from the bottom edge on each sideand drill a 1/4” hole through the tail section and theundertail on each side.

12) place the undertail into position in the stock tail sec-tion, measure 3.5” from the bottom edge and drill a1/4” hole through the tail section and the undertail oneach side.

13) Trim the stock inner fender around the key lock asshown.

17) Replace the stock tail section using the stock fasteners andplace the peice of doubled over heat shield on the right sideresting on the subframe and held down with the tail sectionbolt in the back. DO NOT REPLACE THE GLOVE BOX!

18) Place the undertail into position in the stock tail sec-tion, starting from the top and then spread the lowerportion of the tail section to slide into position. Makesure your signal wires are not touching the exhaust.

19) Use the 2 plastic screw rivets to mount the undertail tothe tail section as shown. Your done!

16) Mount the license plate brackets. We recommendmounting the brackets right behind the LED turn signals.Attach the 2 - “L shaped” brackets to license plate then linebracket up to the Undertail, mark the holes and drill.

15) Clip off the stock wiring connectors from the rear turnsignals and connect to the LED signals on the undertail.Make sure when mounting on the bike, that wires arenot touching the exhaust in any way.

14) Place supplied heat shield on the inside of the tail asshown on top of the foam.