Two Brothers Racing Kawasaki KLR650 - Manual

V.A.L.E.
V a r i a b l e a x i s l o c k i n g e x h a u s t
TM
Parts List
IMPORTANT - PLEASE READ CAREFULLY
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 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
2008 Kawasaki
KFX450R
V.A.L.E.™ Complete Exhaust System with M-7 Aluminum Canister
Part # 005-1660106V
Qty. Description Part Number
1 Muffler Canister M-7 Aluminum 005-166-206M
1 Stainless Steel S-Bend Slip-On Tube 005-16601S
1 Stainless Steel Header 005-16601H
1 HARDWARE KIT 005-166-3C
1 5mm Long Handle Ball end hex key 005-9-18610
4 6x14mm Socket Head Cap Screw 005-SH614
4 6mm Lock Washer 005-WL6
2 TBR Script Logo Yellow Decal 4” 015-10208-A
1 USFS Approved Spark Arrestor (installed) 005-106S
Care & Cleaning
Care & Cleaning
Keep system free of dirt and moisture. Store in a cool, dry place. Make sure vehicle is
completely cool before maintenance.
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.
Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft,
clean cloth.
Titanium Header System: Polished titanium pipes will experience color shift ranging
from deep blue/purple through amber after a few heat cycles. This is a normal
characteristic of high quality titanium. Clean using a mild water based spray cleaner.
Always apply cleaner or polish with a soft, clean cloth.
Polished Aluminum Canisters: Use an aluminum or mag wheel polish to restore the
bright finish to factory spec.
Brushed Aluminum Canisters: Clean using a mild water based spray cleaner. Always
apply cleaner or polish with a soft, clean cloth.
Carbon Fiber Canisters: Clean using a mild water based spray cleaner. Always apply
cleaner or polish with a soft, clean cloth. 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 (Road - #005-10038, Offroad - #005-10038MX) that include
everything you need to easily do it yourself.
Titanium Mufflers: For cleaning use a mild water based spray cleaner. Always apply
cleaner or polish with a soft, clean cloth. 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 (Road - #005-10038, Offroad - #005-10038MX) that include
everything you need to easily do it yourself.
Repack all road canisters at the first signs of packing material deterioration. Part #005-10038
Repack all offroad canisters after every 10 hours of use. Part #005-10038MX
NEVER dyno test your bike with carbon fiber or titanium canisters installed - the
intense heat and lack of cooling air can quickly burn through the canister material. Two
Brothers Racing does not provide a warranty for burned canisters.
Make sure the quad is completely cool before starting
the installation. Make sure the quad is secure on a
level surface and the wheels are chocked to prevent
the quad from rolling.
Remove the bolts securing the OEM muffler to the
frame.
Loosen the OEM clamp connecting the slip tube to
the header. This clamp will not be re-used.
Carefully remove OEM muffler assembly from quad.
Remove the OEM head pipe and install the new TBR
head pipe.
Use the 6 x 14mm bolts and split lock washers to
loosely attach the X-Lite™ ring to muffler inlet . (See
V.A.L.E. Assembly Detail below)
Carefully slide TBR muffler assembly onto the OEM
header making sure that the TBR slip-tube is fully
inserted.
Attach muffler canister to frame using the OEM bolt.
Leave loose for now.
Use the OEM bolt to secure the slip-tube to the frame
and tighten.
Securely tighten the 4 (four) 6 x 14mm hex head
bolts of the V.A.L.E. assembly when proper muffler
alignment is reached.
Securely tighten the muffler bolt last.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Double check to make sure that all hardware is
securely tightened.
Before you run the quad, 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 quad and enjoy. It is normal for
some white smoke to appear the first time you
start the quad. 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.
12.
13.
Muffler Inlet
X-Lite™ Ring
Slip Tube
V.A.L.E.™ Assembly Detail