Vulcan Full System Instructions
Installation Instructions
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 head pipe hardware.
8.
Attach muffler mount to OEM mount using original
mounting bolt with supplied nut and washer.
9.
Tighten all hardware starting with header, barrel clamp,
and mounting bracket once exhaust is in position with
adequate clearance from swing arm.
Kawasaki
Vulcan S 650
Full Exhaust System
Part # 005-4200199-B
Parts List
Qty.
1
1
1
1
1
1
1
Description
Comp-S Barrel Clamp
Header Assembly
O2 Sensor Kit
Nylon Nut
Washer 10mm
Permatex Anti-seize Lubricant
Part Number
Stainless
005-27-61MSH
005-42001H
005-92-22KIT
005-NN11
005-WF10
031-P09175
3.
Remove muffler mounting bolt.
4.
Lower OEM exhaust assembly. Remove O2 sensor.
5.
Attach the TBR header assembly using OEM hardware
and gaskets. Leave loose for now.
6.
Apply small amount of anti-seize to O2 sensor threads
and install O2 sensor with adaptor into head pipe.
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.
Care & Cleaning
Care & Cleaning
Keep system free of dirt and moisture. Store in a cool, dry place. Make sure
vehicle is completely cool before maintenance.
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 vehicle and
exhaust system are completely cool before starting the installation. Also, make
sure the vehicle is secure on a center stand or ideally a service lift during
installation. Be sure to save all stock components for possible use later.
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.
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.
7.
Slide supplied barrel clamp over muffler inlet and install
muffler onto mid-pipe.
Repack all road canisters every 3,000 miles. Part #005-10038
Repack all Off road 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.
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