Two Brothers Racing Kawasaki KLR650 - Manual

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
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.
2. Remove right side panel.
3. Remove upper muffler mounting bolts.
4. Loosen muffler joint clamp.
5. Remove muffler assembly.
6. Attach S1R muffler to TBR slip tube using supplied hook
springs. Loosely install barrel clamp onto slip tube inlet.
7. Install muffler clamp onto muffler.
Qty. Description Part Number
1 S1 Muffler Canister Varies
1 Muffler Clamp 005-2C-S1
1 S1 Slip-On Tube 005-40104S
1 Barrel Clamp 005-27-58MSH
2 Spring 005-S45
1 8x75mm Socket Head Cap Screw 005-SH875
1 Spacer 005-S-34
1 8mm Flat Washer 005-WF8
1 8mm Flange Nut 005-FN8
1 Spring Puller 005-SP
1 Permatex Anti-Seize 031-P09175
Kawasaki
KLR650
Slip-On Exhaust System
Part # 005-4010406-S1
8. Install muffler and slip tube into mounting position.
9. Install S1R mounting hardware bolt, washer, clamp,
spacer, and nut. Securely tighten.
10. Securely tighten the lower muffler barrel clamp.
11. Re-install right side panel.
Double check to make sure that all hardware is fully
tightened.
12. 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.