Installation Instructions V.A.L.E. TM 2003-04 Yamaha 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 R6 1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on the sidestand or ideally a srvice lift. 2. Remove the stock muffler at the passenger footpeg bracket and where it attaches to the stock headers. 3. Remove the rear turn signals and replace with the provided flush mount turn signals. Use the scotch locks to splice into the stock wiring. We recommend sealing the connector with electrical tape or shrink tubing. 4. Remove the passenger footpegs. Install the hanger bracket with the 8mm x 35mm bolts and washers provided. 5. Connect the new S-bend pipe to your stock header, using the supplied T-bolt clamp. You will NOT be reusing the exhaust gasket. Leave loose for now. 6. Install VALE adapter Kit to muffler canister using the supplied kit instructions. 7. 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 pipe. Wipe off the excess sealant that will squeeze out. 8. Carefully slide the muffler clamp over the muffler. (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.) Attach the clamp to the hanger bracket using the 8mm x 40mm bolt, washers and nut provided. 9. Be sure everything is properly aligned and tighten all hardware. Install the two springs. V.A.L.E.™ High mount Slip-on Exhaust System with M-2 Canister Part # 005-220406HM, 005-220407HM, 005-220408HM, 005-220419HM, 005-220420HM 10. 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. Parts List Qty. Description Part Number 1 Muffler Canister 1 Canister Clamp 1 Stainless Steel S-Bend Tube 1 HARDWARE KIT 1 VALE Adapter Kit 1 High Mount Bracket 2 80mm Swivel Hook Spring 1 Barrel Clamp 2 8 x 35mm Socket Head Cap Screw 1 8 x 40 mm Socket Head Cap Screw 3 8mm Washers 1 Nylon Lock Nut 4 Blue Scotchlocks 1 Pair Turn Signals 1 Permatex Ultra Black Gasket Maker 1 T20 Torx Screw Wrench 1 TBR Sticker Kit Varies Varies 005-2204HT 005-22H-3 005-2-1-V 005-22HB 005-S80 005-27-65MSH 005-SH835 005-SH840 005-WF8 005-NN8 005-BS 005-88T 031-P22072 005-9-15820 015-10212 IMPORTANT - PLEASE READ CAREFULLY 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 center stand or ideally a service lift during installation. Be sure to save all stock components for possible use later. Care & Cleaning 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 Mufflers: 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 (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. Repack all road canisters every 3,000 miles. Part #005-10038 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.
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