BMW R1100S
Catalytic Eli. Exhaust System
IMPORTANT - PLEASE READ CAREFULLY
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.
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.
OE Exhaust Detail
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. Remove the seat, rear side panels and number plate.
3. Remove the stock canister assembly, catalytic converter and O2
sensor. Loosen the header pipes and crossover pipe, do not
remove the header pipes.
4. Be sure to coat the threads of the O2 sensor with the included
packet of hi-temp anti-seize. Install the O2 sensor into the collector.
C4 Canisters
5. Install the collector using the stock hardware. Leave loose for
now.
Parts List
QTY.
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DESCRIPTION
C4 ROUND MUFFLER (10”, LEFT SIDE)
C4 ROUND MUFFLER (10”, RIGHT SIDE)
MUFFLER CLAMPS
SLIP-ON “Y” CONNECTOR
CATALYTIC ELIMINATOR TUBE
MUFFLER HANGER BRACET
32MM X 15MM SPACER
LICENSE PLATE HOLDER
LITZ N’ BOLTS
8MM X 30MM FLANGE BOLTS
8MM FLANGE NUTS
8MM NYLOCK NUTS
8MM WASHERS
8MM X 50MM SOCKET HEAD CAP SCREW
HITCH PINS
75MM SPRINGS
ANTI SEIZE
HI-TEMP SEALANT
TWO BROTHERS RACING STICKERS
6. Install the slip-on connector onto the collector reusing the BMW
clamp. Leave loose for now.
PART NUMBER
VARIES
VARIES
VARIES
005-8504N
005-8501N
005-8504M
005-S-32
005-8504L
005-8504LT
N/A
N/A
N/A
7. Install the canister hanger bracket onto the two horizontal posts
that supported the stock mufflers (ref. illustration). It may be necessary to lightly tap the bracket into place with a hammer. Make
sure the hanger bracket is fully engaged onto the posts and that
there is at least 1/4” of post extending past the new hanger bracket. Drill one 2.5mm hole through each post and install the supplied stainless steel hitch pin clips. These clips will prevent the
mufflers from sliding back on the hanger posts.
N/A
N/A
005-S75
031-P09175
031-P22072
015-10197
8. Place a bead of the hi-temp sealant on the outside edge of the
slip-on connector that go into the canisters. Slide the canisters
onto the end of the s-bend connector. Wipe off the excess sealant
that will squeeze out. Rotate the canisters to the proper orientation and install the springs.
9. Assemble the canister clamps and hardware (ref. illustration).
Leave loose for now.
10. Install the slip-on connector/canister assembly onto the collector.
Attach the slip-on connector/canister assembly to the hanger
bracket using the 8mm x 50mm bolt. Carefully align all pipes,
canisters and hardware. When everything is in place, tighten all
hardware and clamps. Don’t forget to tighten the front head pipe
nuts, crossover pipe clamp and O2 sensor. Connector the license
plate lights to the wiring harness.
11. Be sure to allow the sealant to dry per the manufacturer’s
instructions before starting the bike. 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/manufac-
Centerstand Support Detail
The kit comes with two (2) 8mm x
30mm bolts that are to be used as
new centerstand stops as the old
one went away with the catalytic
converter. Drill two (one on each
side) 8mm holes in the lower flat
portion of the catalytic converter
support castings on the frame.
Install one bolt with the head facing down (ref. photo) along with one
jam nut and lock nut. These bolts become the new centerstand
stops. Adjust the depth of the bolts as needed to properly support
the centerstand.
License Plate Hanger Detail
Muffler Hanger Bracket
32mm x 15mm Spacer
NOTE: Muffler view
may differ depending
on the type of canister
you ordered.
Muffler Clamp
License Plate Hanger
View from rear of bike
Lighted Bolts
(*note orientation
of light coverage
and wire routing
behind license
plate hanger)
BMW R1100S Cat Eli C4 Instructions.qxd