Two Brothers Racing Suzuki DR-Z400S/SM - Manual

Parts List
Installation Instructions
Qty. Description Part Number
1 Muffler Canister 005-163-206M/207M
1 S-bend Tube with V.A.L.E. Assembly 005-16301S
1 HARDWARE KIT 005-163-3
2 X-Ring (half) 005-7-2-3
2 Billet Solid Mount 005-163-S
1 Barrel Clamp 005-27-57MSH
1 8mm Flat Washer 005-WF8
4 6x14mm Socket Head Cap Screws 005-SH614
4 M6 Split Lock Washer 005-WL6
1 8x60mm Socket Head Cap Screw 005-SH860
1 Ball End Hex Wrench 005-9-18610
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
8. Tighten the 4 6x14mm socket head cap screws joining
the muffler to the mid-pipe.
9. . Tighten the barrel clamp.
10. Use OEM mounting hardwarend to re-install the
heat shield.
11. Re-install side panel.
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.
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 every 3,000 miles. 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.
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 vehicle and
exhaust system are completely cool before starting the installation. Also,
make sure the vehicle is secure on a centerstand or ideally a service lift during
installation. Be sure to save all stock 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 sidestand or ideally a rear service stand.
2. Remove right side panel.
3. Remove muffler assembly from motorcycle leaving
head pipe attached. You will need to remove the
heatshield too.
4. . Attach the TBR mid-pipe to the muffler using the 4
socket head cap screws and split lock washers provided.
Do not tighten yet.
5. Remove the rubber bushing from the rear upper
muffler mount on the subframe. Slide the supplied
barrel clamp onto the mid-pipe at pipe joint.
6. Attach the 2 supplied solid mount spacers in the frame
(1 on each side) and attach the muffler to the mororcycle
using the supplied 8x60mm bolt and washer with OEM
nut. Leave loose for now. Use threadlock.
7. . Make sure muffler is lined up straight and tighten
upper muffler mount.
2005-10 Suzuki
DR-Z400S
V.A.L.E.™ Slip-on Exhaust System with M-7 Canister
Part # 005-1630406V / 005-1630407V
Muffler Inlet
X-Lite™ Ring
Slip Tube
V.A.L.E.™ Assembly Detail