beautypg.com

Two Brothers Racing Kawasaki ZX-12R User Manual

Two Brothers Racing For the car

background image

Mfg: Kawasaki Make: ZX-12R
Year: All
Product: Flange-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 nuts holding the stock canister onto the

flange. Loosen the hardware that holds the canister to
the passenger footpeg and remove the canister from the
bike. You will reuse the stock flange gasket.

3. Before bolting our new muffler on you will have to cut off

most of the tubing that extends past the flange face (ref.
picture on right). Measure 1/2” back from the flange then
cut and debur the tube.
This tubing that you will remove
is part of the OEM design that allows the bike to meet
production sound standards. It is not a performance
enhancing device. Conversely it actually restricts the
flow of exhaust gas. Removing it will not adversely affect
the running condition of your motorcycle.

4. Slip the new canister onto the stock pipe flange, re-using

the stock gasket. Use the 8mm x 25mm bolts to attach
the new canister and tighten evenly until the flange sur-
faces are mated.

5. Install the ZX-12R bracket to the passenger footpeg

bracket using the stock hardware.

6. 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.)
Locate both tabs of the canister clamp on the outside of
the ZX-12R bracket. Use the 8mm x 20mm bolt and nut
to secure it.

7. Before you run the bike, clean off all fingerprints and dirt,

as any oily residue will etch the metal and become some-
what 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/manufac-
turing 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

ZX-12R Flange-On Instructions.qxd

Installation Instructions

Care & Cleaning / Warranty

Flange Detail

1/2” Cut on dotted line.

Qty.

Description

Part Number

1

Muffler Canister

Varies

1

Canister Clamp with Rubber Liner

Varies

1

HARDWARE KIT

005-71-3

1

ZX-12R Muffler Bracket

005-71B

4

8 x 25mm Flange Bolts

005-FB825

1

8 x 20mm Socket Head Cap Screw

005-SH820

1

8mm Washer

005-WF8

1

8mm Flange Nut

005-FN8

2

Two Brothers Racing Stickers

015-10208-A

8mm x 20mm bolt
and flange nut. 8mm
hole in bracket goes
on this end.

10mm hole in
bracket goes
on this end

Canister Clamp Detail