Two Brothers Racing Suzuki SV650 - Manual

Mfg: Suzuki Make: SV650
Year: 2003
Product: Slip-On Exhaust System
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. Loosen the canister hardware at the passenger footpeg
bracket. Do not remove yet.
3. With your Sawzall or a simple hacksaw, cut the stock
header pipe perpendicularly, 2 inches from the rear weld
on the pipe. See photo and diagram. Remove stock muf-
fler. Be sure to remove any sharp edges from the cut
edge.
4. Place a bead of hi-temp sealant on the outside edge of
the header that goes into the s-bend. Using the supplied
T-Bolt clamp install the s-bend onto the end of the head-
ers. Leave loose for now. Wipe off the excess sealant
that will squeeze out.
5. Place a bead of the hi-temp sealant on the outside edge
of the s-bend that goes into the canister. Slide the TBR
canister onto the end of the s-bend. Wipe off the excess
sealant that will squeeze out.
6. Carefully slide the canister clamp over the canister.
(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 on the outside of the passenger footpeg.
Use the stock hardware to secure it. Leave loose for
now.
7. Make sure everything is aligned and tighten all hardware
starting at the front of the bike and working your way
backward. Affix the springs.
8. 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
Canister Clamp Detail
Front
SV650 (2003) Slip-On Instructions.qxd
Installation Instructions
Care & Cleaning / Warranty
Standard Mount
Cutting Location Detail
cut at 2 inches from weld
OE exhaust system after cutting
Parts List
Qty. Description Part Number
1 Canister (slip-on, right exit Varies
1 Canister Clamp Varies
1 Stainless Steel S-Bend -
Standard Mount 005-10104T
2 80mm Springs 005-S80
1 T-Bolt Clamp (27-65MSH) 005-27-65MSH
1 Packet of Hi-Temp Sealant 031-P22072
2 TBR Stickers 015-10197
Cut at 2 inches from weld