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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