ZX10R Full Exhaust Instructions

ZX10R Full Exhaust Instructions
Installation Instructions
1.
Make sure the bike is completely cool before starting the
installation. Make sure the bike is secure on a centerstand or
ideally a service lift.
2.
Remove side covers and seat.
8.
Install Headers. Make sure the OEM copper gasket is
between cylinder head and exhaust pipes.
9.
Attach TBR muffler to slip-on tube using the 4 6x14mm
S.H.C.S. and lock washers provided. Leave loose for now.
Kawasaki
ZX-10R
V.A.L.E.™ Full Exhaust System with M-2 Canister
Part # 005-199010xV
Parts List
Qty.
Description
Part Number
1
1
1
1
1
1
2
1
6
1
1
1
1
4
4
Muffler Canister
4-2-1 Header Assembly
Slip-on Tube HARDWARE KIT
X-Ring Kit
Fender Bracket
Lighted License Plate Bolt
Turn Signals (set of 2)
But Splice Connectors
Barrel Clamp
Zip Ties
Zip Tie Tab
8x50mm Socket Head Flat (Black)
6x20mm Socket Head Cap Screw
6mm Flange Nut
Varies
005-19901H
005-19904S
005-199-3C
005-7-2-3KIT
005-19904B
005-8504LTZ
005-88T2
005-BS1614
005-27-66MSH
005-ZT458B
005-ZTM4
005-SHF850
005-SH620
005-FN6
IMPORTANT - PLEASE READ CAREFULLY
Two Brothers Racing products are intended for closed course competition purposes only.
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.
3.
Remove lower rear exhaust cover.
4.
Remove exhaust valve cables from servo under seat.
10. Slide supplied barrel clamp on end of slip tube where it will
meet TBR header assembly. Install the TBR muffler assembly
and attach using the S.H. flat bolt and OEM nut to secure the
rear muffler mount.
*Keep servo plugged
into harness but cables
will not be used.
5.
Remove OEM muffler assembly.
6.
Remove lower left and right fairings
7.
Remove OEM header assembly (remove lower radiator
support bracket to swing radiator out for more room to
remove header nuts).
11. Check alignment and tighten muffler and the 4 6x14mm
V.A.L.E.™ S.H.C.S.
Installation Instructions
WIRING DIAGRAM
(
13. Install TBR fender eliminator kit using the 4 6x14mm S.H.C.S.
and supplied nuts to rear frame.
Plate Lights
ck
17. Check for clearance between exhaust and all other parts and
make adjustments if needed.
18. Double check all your work.
19. 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. Also, remove any
plastic film from the name badge(s and or canister clamp(s).
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.
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.
* For best overall performance a JuiceBoxPro (001-199) is recommended
Polished Aluminum Canisters: Use an aluminum or mag wheel polish to restore the bright finish to factory
spec.
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.
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.
d
Bla
16. Re-install seats and covers.
Care & Cleaning
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.
Re
15. Start engine and make sure no leaks are found.
Care & Cleaning
Keep system free of dirt and moisture. Store in a cool, dry place. Make sure vehicle is completely cool before
maintenance.
Brushed Aluminum Canisters: Clean using a mild water based spray cleaner. Always apply cleaner or polish
with a soft, clean cloth.
ck
Varies
005-19901H
005-19904S
005-199-3C
005-7-2-3KIT
005-19904B
005-8504LTZ
005-88T2
005-BS1614
005-27-66MSH
005-ZT458B
005-ZTM4
005-SHF850
005-SH620
005-FN6
Bla
Part Number
Muffler Canister
4-2-1 Header Assembly
Slip-on Tube HARDWARE KIT
X-Ring Kit
Fender Bracket
Lighted License Plate Bolt
Turn Signals (set of 2)
But Splice Connectors
Barrel Clamp
Zip Ties
Zip Tie Tab
8x50mm Socket Head Flat (Black)
6x20mm Socket Head Cap Screw
6mm Flange Nut
d
Description
1
1
1
1
1
1
2
1
6
1
1
1
1
4
4
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Wiring Harness
12. Tighten barrel clamp.
14. Attach turn signals and plate light bolts using the wire splice
connectors supplied to the correct wires in the harness as
shown in the Wiring Diagram.
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