So I just bought a new exhaust from PPM Custom and installed it tonight. My first reaction after starting the bike was "#@%$ that's loud!!!" Then I noticed the FI light. At first I thought it was on only because the exhaust control valve and actuator were removed with the stock exhaust so there were unplugged wires, but then I started to think. Could it be a problem with the lack of back pressure? I certainly don't want to burn up my valves!!

First off, the most likely culprit to your predicament is the wiring harness under your seat leading to the ECM (assuming that you have a k6/k7 gsxr). Your initial thought is most likely right. There is a black/brown wire that must be removed from the harness so that you don't get the FI light. Once you remove it you should be fine and ready to ride:punk.

I installed my Yosh R-55 full system myself on my k7 750 and the instructions from the Yosh website specifically said to remove that particular wire because it is related to the servo motor that controls the SET valve.

I don't remember off the top of my head which pin corresponds to the wire but if you google the yosh r-55 instructions then you will find it.

Thanks a lot, I assumed that was the problem but don't even pretend to understand the wiring on that beast.

From Yoshimura, All R bikes with the SET (Suzuki Exhaust Tuneing) will throw a FI light and the bike will be put into a power limited fail-safe mode when you change the exhaust. This is due to a servo that is trying to regulate the exhaust. There are instructions on how to remove the "Power Wire" to the SET from the ECU in the in all Yoshi Exhaust systems. This will remove the annoying red light and the Code thrower. I just did this the other day and it worked perfectly. I will link my instructions from Yoshi with detailed pics. Remember that this might be different exhaust than yours. Please Sticky this and add SOLVED: to the topic, as it is the most common problem with new exhaust on new bikes.

PASTED INSTRUCTIONS from PDF:
1 It is necessary to properly disable the Suzuki SET (Suzuki Exhaust
Tuning) system by following the steps listed below. Without
properly disabling the SET system the engine will run in a power
limited fail-safe mode.

2 Remove rider seat and metal brace located over the ECU by
removing the four bolts (see Fig. 1).

3 With ignition in OFF position, disconnect the black wire harness
plug from the ECU (see Fig. 2).

4 Remove the orange cap by pressing the small orange tabs apart
and pulling the orange cap off (see Fig. 3).

5 Pull out the black wire with brown stripe (see Fig. 4). When you
hold the black plug with the locking tab facing down, the black
wire with brown stripe is in the top row in the slot from the left
(see Fig. 5). Insert a very small flat head screwdriver into the hole
that the arrow is pointing to in Fig. 5. Gently pry down with the
screwdriver to unlock the wire and pull on the black wire with
brown stripe from the rear of the plug to remove.
NOTE: If you don’t have a small flat head screwdriver use a
regular paper clip to make one (see Fig. 6).

6 Completely seal off the disconnected wire to prevent possible
electrical problems. Dip disconnected wire in liquid electrical
tape. After liquid electrical tape is dry, slide a 1.5” piece of heat
shrink tubing 1” over the end of the disconnected wire and fold
the remaining 0.5” of heat shrink tubing to create a water tight
seal. Slide a slightly larger piece of heat shrink tubing over the
folded section of heat shrink tubing. Using a heat gun, shrink the
heat shrink tubing to create a water tight seal. Secure
disconnected wire to harness using a zip tie.

7 Reinstall orange cap onto black wiring harness plug and
reconnect plug to ECU.

8 Reinstall the metal brace and rider seat.

9 Completely remove the exhaust valve cables from the EXCVA
servo (refer to the factory service manual for removal
instructions).
http://www.yoshimura-rd.com/images/product/pdf/1104072.pdf


Thanks and hope this helps.

Alright, so I removed the power wire and now I have a whole new problem. The FI light is still on and now the bike won't start. When I turn it on and before attempting to start, the fuel injection system makes a clicking noise. When I try to start the bike, it is turning over but does not fire. Any ideas?

Well, I guess you need to do the bridge wire thing to set eh bike in dealer mode to see what code your throwing. Might just wanna google dealer code and you bike model. I'm no mechanic so.. I guess after that i would take it to the shop.

You have to make sure these directions are Bike model specific and Exhaust model specific. I have been told 2 different wires now on my 600 for the Akrapovic Full System and neither one worked and now I have 2 wires that i had to splice back together. Try finding info directly related to your bike and the exhaust you have.

[QUOTE=turbo0450;2969554]From Yoshimura, All R bikes with the SET (Suzuki Exhaust Tuneing) will throw a FI light and the bike will be put into a power limited fail-safe mode when you change the exhaust. This is due to a servo that is trying to regulate the exhaust. There are instructions on how to remove the "Power Wire" to the SET from the ECU in the in all Yoshi Exhaust systems. This will remove the annoying red light and the Code thrower. I just did this the other day and it worked perfectly. I will link my instructions from Yoshi with detailed pics. Remember that this might be different exhaust than yours. Please Sticky this and add SOLVED: to the topic, as it is the most common problem with new exhaust on new bikes.

Great Info i've been looking for these instruction and finally found it!!! I think??
Next question is does this apply to GSXR 1000 k7/k8??? Have the exact same problem with a set of yosh dual tri ovals with racing yosh mid pipe that didnt have an o2 sensor mount nor instructions that you stated???
Still have my set valve cuz the pipe is only a half system.
:banghead:scratch