Two Brothers Racing Suzuki DR650 - Manual

1998-07 Suzuki
DR650
Stainless Steel Slip-on Exhaust System with M-7 Aluminum Canister
Part # 005-640406
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
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. Loosen the stock muffler hardware at the rear fender. You
will reuse this hardware later.
3. Take off the bolt in the middle of the header pipe (under the
plastic), and remove the muffler and rear pipe.
4. Remove the stock muffler assembly.
5. Slide the V.A.L.E ring over s-bend tube and loosely attach
to TBR muffler assembly using the 4 (four) 6x14mm socket
head cap screws and split lock washers provided. Do not
tighten yet.
6. Slide muffler assembly into the stock headpipe and loosely
attach muffler and s-bend using O.E.M. hardware. Do not
tighten yet.
7. Tighten the 4 6x14mm V.A.L.E. bolts once the muffler is
aligned straight. Next, tighten the s-bend mounting bolt
and then the muffler mount. The upper muffler mount is
rubber mounted with a supplied spacer inside the rubber
grommet. Make sure this spacer is inside the rubber.
8. 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.
Qty. Description Part Number
1 DR650 Muffler Canister M-7 Aluminum 005-64-206M
1 DR650 Stainless Steel S-Bend Tube 005-6404S
1 Spacer (Installed) 005-64-24
1 Rubber Grommet (Installed) 005-9307K62
1 HARDWARE KIT 005-64-3
1 X-Ring Kit 005-7-2-3KIT
1 TBR Sticker Kit 015-10212
1 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.