Two Brothers Racing Honda 919 - Manual

Mfg: Honda Make: 919
Year: All
Product: Single Slip-On Exhaust System
Parts List
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.
Chrome Header System: Chromed header tubing will turn blue close to the exhaust ports, this is normal. To pre-
vent corrosion you must keep the header pipes clean.
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 fiber-
glass packing inside is in good condition and not burned out, as exhaust heat inside an empty canister will deterio-
rate 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 mufflers 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 disclaims all responsibility for consequential and incidental damages or any other losses
arising from the use of these products or parts.
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. Remove the grab rail, seat and tail section.
3. Remove the 6mm x 10mm buttonhead bolts from the
underside of the rear fender (see picture).
4. Loosen the clamps that hold the stock canisters at the
“Y” connector pipe. Remove the stock mufflers.
5. You will need raise and support the rear of the motorcy-
cle and remove the rear shock in order to remove the “Y”
connector pipe. The rear shock must be removed in order
to remove the “Y” connector pipe from the motorcycle.
6. After removing the “Y” connector pipe reinstall the rear
shock. Be sure to torque all bolts to factory specifications.
7. Replace the stock rear brake line with the stainless steel
line provided. The new brake line does not follow stock
routing. Be sure the brake line does not touch the
exhaust system.
8. Install the new TBR bracket on the underside of the rear
fender (see picture) using the supplied 6mm x 20mm
bolts.
9. Place a bead of the hi-temp sealant on the outside edge
of the header that goes into the s-bend. Slide the s-bend
onto the end of the header. Wipe off the excess sealant
that will squeeze out. Use the stainless steel T-bolt clamp
to secure it. Leave loose for now.
10. Place a bead of the hi-temp sealant on the outside edge
of the s-bend 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.
11. Carefully slide the canister clamp over the canister.
(Note: The stainless steel canister clamp and the name
badge on the canister come from the factory with a clear
plastic protective film. Please remove this film before
operation.) You may need to twist and turn the S-bend a
little to get it in the right place. Locate both tabs of the
canister clamps toward the inboard and underside of the
rear fender. Use the 8mm x 16mm hardware to secure
the clamps. Leave loose for now.
12. Make sure everything is aligned and tighten all hardware.
Some tweaking may be required for proper alignment.
Be sure you have proper clearances between the
exhaust system and the motorcycle. Affix the connector
springs to the muffler.
13. Reinstall the grab rail and tail section. Be sure to check
the operation of the key prior to reinstalling the seat as
the lock mechanism can easily be jammed during seat
cowl installation. DO NOT INSTALL SEAT IF KEY CAN-
NOT BE REMOVED FROM LOCK MECHANISM.
Reinstall seat only after lock works properly.
14. Be sure to allow the sealant to dry per the manufacturer’s
instructions before starting the bike. 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.
IMPORTANT - PLEASE READ CAREFULLY
Bracket Detail
919 Single Slip-On Instructions.qxd
Installation Instructions
Care & Cleaning / Warranty
Stock Bolts
Underside Detail
Qty. Description Part Number
1 Muffler (17.5 “, Right Exit) Varies
1 Muffler Clamp with Rubber Liner Varies
1 Stainless Steel S-Bend 005-9004T
2 80mm Springs 005-S80
1 T-Bolt Clamp (27-61MSH) 005-27-61MSH
1 Single Slip-On “L” Mounting Bracket 005-90B
2 6mm x 20mm Socket Head Cap Screws N/A
1 8mm x 16mm Socket Head Cap Screws N/A
1 Rear Stainless Steel Brake Line 012-HN90-SR-1
1 Packet of Hi-Temp Sealant 031-P22072
2 TBR Stickers 015-10197