Two Brothers Racing Suzuki GSX-R600 / GSX-R750 (96-99) Flange-On Exhaust System - Manual

Suzuki GSX-R600 / GSX-R750
(96-99)
Flange-On Exhaust System
Parts List
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 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 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 sidestand or
ideally a rear service stand.
2. Remove the nuts/bolts 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. Install the stock flange gasket into the canister. Slip the can-
ister onto the end of the stock exhaust flange. Use the 8mm
x 20mm bolts provided to secure it. Go ahead and tighten the
bolts evenly and fully.
4. Carefully slide the canis-
ter clamp over the canis-
ter. (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.) Using the alu-
minum spacer, place it
between the clamp and
the footpeg bracket.
Locate both tabs of the
canister clamp on the out-
side of the spacer. Use the 8mm x 50mm bolt provided to
secure it.
5. 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.
IMPORTANT - PLEASE READ CAREFULLY
GSX-R (Old Generation) Flange-On Instructions.qxd
GSX-R750 (1996-99) OE Exhaust System
Installation Instructions
GSX-R600 (1997-00) OE Exhaust System
Care & Cleaning / Warranty
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 & 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 fiberglass packing inside is
in good condition and not burned out, as exhaust heat inside an empty canister will
deteriorate 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 muf-
flers 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 dis-
claims all responsibility for consequential and incidental damages or any other losses
arising from the use of these products or parts.
QTY. DESCRIPTION PART NUMBER
1 17.5" MUFFLER WITH #34 FLANGE -
C2 MUFFLER (#E028 WITH 93-95 ORIENTATION) VARIES
C4 MUFFLER (#E088 WITH 93-95 ORIENTATION) VARIES
C5 MUFFLER (#E128 WITH 93-95 ORIENTATION) VARIES
1 MUFFLER CLAMP WITH RUBBER LINER VARIES
1 8X50MM SOCKET HEAD CAP SCREW NA
3 8X20MM SOCKET HEAD CAP SCREWS NA
1 18MM SPACER 005-S-18
1 8MM WASHER NA
2 TBR 7" SCRIPT DECALS 015-10197