Two Brothers Racing BMW R1100GS - Manual

We recommend that this performance exhaust system
be installed by a qualified motorcycle technician. If you
have any doubts as to your ability to install this exhaust
system, please consult with your local motorcycle deal-
er. Read all instructions first before starting installation.
Make sure the motorcycle and exhaust system are com-
pletely cool before starting the installation. Also, make
sure the bike is secure on the sidestand or ideally a rear
service stand during installation. Be sure to save all
stock exhaust components for possible use later.
1. Make sure the bike is completely cool before starting the
installation. Make sure the bike is secure on the side-
stand or ideally a rear service stand.
2. Unscrew the O2 sensor. Remove the stock canister/cat-
alytic converter unit from the bike. CAUTION-the stock
exhaust is very heavy, be careful not to drop it! Do not
remove the headers.
3. Place a bead of the hi-temp sealant on the outside edge
of the header that goes into the catalytic eliminator col-
lector. Slide the catalytic eliminator collector onto the end
of the header. Wipe off the excess sealant that will
squeeze out. Use the t-bolt clamp to secure the catalytic
eliminator collector onto the stock header. Leave loose
for now.
4. Be sure to coat the threads of the O2 sensor with the
included packet of hi-temp anti-seize. Install the O2 sen-
sor into the collector. Turning the sensor in the counter-
clockwise direction a few times then screwing it clockwise
to install will help make it easier to install and prevent the
wire from binding.
Low Mount:
Install the hanger
bracket (B) and
the saddlebag
support bracket
(A) per photo illus-
tration using the
hardware provid-
ed. Reinstall the
BMW plastic bag
mount bushing
onto the new sad-
dlebag support
bracket using the
stock hardware to
secure.
5. Place a bead of the hi-temp sealant on the outside edge
of the collector that goes into the canister. Slide the TBR
canister onto the end of the S-bend pipe. Wipe off the
excess sealant that will squeeze out.
6. Install the 8mm spacer onto the canister mount stud.
Carefully slide the muffler clamp over the muffler and
onto the mounting stud. (Note: The stainless steel canis-
ter clamp and the name badge on the canister come from
the factory with a clear plastic protective film. Please
remove this film before operation.) Use the stock hard-
ware to secure. Leave loose for now.
Low Mount: Locate both tabs of the canister clamp on
the inside of the hanger bracket (B). Use a 8mm x 30mm
and 8mm nut to secure. Leave loose for now.
7. Make sure everything is aligned and tighten all hardware.
Affix the connector springs to the muffler.
8. Before you run the bike, clean off all fingerprints and dirt,
as any oily residue will etch the metal and become some-
what 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/manufac-
turing 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.
IMPORTANT - PLEASE READ CAREFULLY
BMW R1100GS Instructions.qxd
Installation Instructions
Standard (High) Mount Low Mount enables full size BMW
saddlebags
B B M M W W R R 1 1 1 1 0 0 0 0 0 0 0 0 G G S S
C C C C a a t t a a l l y y y y t t i i c c E E l l i i . . E E x x h h a a u u s s s s t t S S y y y y s s s s t t e e m m
Parts List
Care & Cleaning / Warranty
QTY. DESCRIPTION PART NUMBER
1 MUFFLER (17.5”, LEFT SIDE) VARIES
1 MUFFLER CLAMP VARIES
1 CATALYTIC ELIMINATOR CONNECTOR TUBE
LOW MOUNT 005-9204N
STANDARD MOUNT 005-9204NH
1 BARREL CLAMP (27-64MSH) 005-27-64MSH
2 80MM SPRINGS 005-S80
1 ANTI SEIZE 031-P09175
1 HI-TEMP SEALANT 031-P22072
2 TWO BROTHERS RACING STICKERS 015-10197
LOW MOUNT HARDWARE KIT
1 SADDLE BAG SUPPORT BRACKET (A) 005-9204A
1 MUFFLER HANGER BRACKET (B) 005-9204B
3 8MM X 30MM SOCKET HEAD CAP SCREWS N/A
4 8MM NYLOCK NUTS N/A
8 8MM WASHERS N/A
STANDARD MOUNT HARDWARE KIT
1 8MM SPACER 005-S-8
Care & Cleaning
Keep system free of dirt and moisture. Store in a cool, dry place. For cleaning use a
mild spray cleaner. Always apply cleaner or polish with a soft, clean cloth.
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.
Carbon Fiber & X-Metal Mufflers: X-Metal CF canisters will shift color from their
original silver color to an amber color after a few heat cycles, similar to the way our
stainless steel headers shift color. 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 / X-Metal CF sleeve. TBR sells repack kits (TBR part #
005-10038) that include new rivets and repack material as well as a drill bit (#30),
making it easy to do yourself. Also, NEVER dyno test your bike with carbon fiber muf-
flers installed - the intense heat and lack of cooling air can quickly cause the CF
material to burn. Two Brothers Racing does not provide a warranty for burned carbon
fiber.
Aluminum Mufflers: Use an aluminum or mag wheel polish such as Mother’s to
restore the bright finish to factory spec.
Warranty
Two Brothers Racing products are intended for closed course competition purposes
only, and therefore are sold “as is” without warranty. Two Brothers Racing specifically
disclaims any warranties of merchantability or fitness for a particular purpose and dis-
claims all responsibility for consequential and incidental damages or any other losses
arising from the use of these products or parts.
Standard (High) Mount Low Mount enables full size BMW
saddlebags