Two Brothers Racing Kawasaki EX250 Ninja - Manual

Parts List
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.
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. Read ALL
instructions before beginning installation.
2. Remove the stock muffler mounting bolts and remove
the stock mufflers, one at a time. Save OEM hardware
for later use.
3. Remove the OEM barrel clamps.
4. Remove the OEM slip tubes.
5. NOTE: The Two Brothers Racing LEFT and RIGHT slip
tubes are not interchangeable and are identified by
their individual stamps: 159-L for the LEFT and 159-
R for the right side tube.
6. Slide a supplied barrel clamp on to each slip tube.
7. Apply a bead of supplied high temp sealant to inside
of each supplied slip tube.
8. Slide each supplied slip-tube onto the stock headers.
Wipe off excess sealant that will squeeze out.
9. Apply a bead of supplied high temp sealant to inside of
each muffler inlet where it slides onto the slip tube.
10. Slide each muffler canister onto each slip tube. Wipe off
excess sealant that will squeeze out.
11. Attach muffler canisters to rear foot peg mounts using
OEM hardware. Make sure that each name badge is
facing outward.
12. Check to be sure that both exhausts are positioned
and aligned correctly. Once you are satisfied with the
position of the exhaust, fully tighten each barrel clamp,
then the muffler mounting bolts.
13. Double check your work to ensure everything is tight
and properly installed.
14. Before you run the bike, clean off all fingerprints
and dirt, as any oily residue will etch the metal and
become 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.
1988-2007 Kawasaki
Ninja EX250
Dual M-6 Slip-on Exhaust System
Part # 005-1590406D
Qty. Description Part Number
1 EX250 M-6 Muffler Canister - Right Side 005-159-204R
1 EX250 M-6 Muffler Canister - Left Side 005-159-204L
1 EX250 Slip Tube - Right Side 005-15904SR
1 EX250 Slip Tube - Left Side 005-15904SL
1 HARDWARE KIT 005-159-3
2 Barrel Clamp 005-27-55MSH
1 Permatex Ultra Black Gasket Maker 031-P22072
1 Sticker Kit 015-10212
Care & Cleaning / Warranty
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 Mufflers: 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 (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.