Two Brothers Racing Kawasaki ZX-636R/6RR - 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 center stand 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 the sidestand or
ideally a service lift.
2. Loosen the clamp that holds the muffler connector pipe to the headers under the bike.
3. Remove the hardware that holds the stock muffler at the passenger footpeg bracket. Take off the muffler.
4. Instal VALE adapter kit using the supplied kit instructions.
5. 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 using the stainless steel T-bolt clamp to attach it to the headers. Leave loose for now. Wipe off the excess
sealant that will squeeze out.
6. Place a bead of the hi-temp sealant on the outside edge of the s-bend that goes into the cansiter. Slide the TBR canister
onto the end of the S-bend pipe. Wipe off the excess sealant that will squeeze out.
7. Install the hi-temp rubber liner onto the muffler clamp if not already done. The liner wraps around the edges of the clamp.
Carefully slide the muffler clamp over the muffler. (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 clamp outside of the
passenger footpeg bracket. Use the stock hardware to sercure it. Leave loose for now.
8. Make sure everything is aligned and tighten all hardware. Affix the connector springs to the muffler.
9. 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.
Kawasaki
ZX-636R
V.A.L.E.™ Slip-on Exhaust System with M-2 Canister
Part # 005-400406M, 005-400407M, 005-400408M
Qty. Description Part Number
1 Muffler Varies
1 Muffler Clamp Varies
1 S-Bend Tube 005-4004N
1 HARDWARE KIT 005-40-3
1 VALE Adapter Kit 005-2-1-V
2 80mm swivel hook spring 005-S80
1 barrel clamp 005-27-61MSH
1 Permatex Ultra Black Gasket Maker 031-P22072
1 T20 Torx Screw Wrench 005-9-15820
1 TBR Sticker Kit 015-10212
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
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.
Care & Cleaning
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.
Repack all road canisters every 3,000 miles. Part #005-10038