Installation Instructions
Installation Instructions
V.A.L.E.
1.
Make sure the ATV is completely cool before starting
the installation. Make sure the ATV is secure on a level
surface and the wheels are chocked to prevent the ATV
from rolling.
2.
Loosen slip-on joint clamp.Remove muffler mounting
bolts and muffler assembly.
3.
Assemble the V.A.L.E.™unit by slipping the S-bend
tube through the X-Lite™ ring. Use the 4 (four) 6 x
14mm bolts and split lock washers to loosely attach the
X-Lite™ ring to muffler inlet. (See V.A.L.E.™ Assembly
Detail below)
4.
Use the supplied threadlock. Slip S-bend into headpipe
Attach muffler to muffler mounts using the 8x25mm Socket Head Cap Screw and 8mm washer provided. 5.
Use the supplied threadlock. Tighten the 4 socket head
cap screws on V.A.L.E. muffler joint in a cross-type
pattern. Securely tighten. 6.
Check your work to be sure all hardware is securely
tightened.
TM
2004-08 Suzuki
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
Z250 Quadsport
V.A.L.E.™ Slip-on Exhaust System with M-7 Canister
Part # 005-1670406V
Parts List
7.
Before you run the ATV, 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 ATV and enjoy. It is normal for some white
smoke to appear the first time you start the ATV. 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
Qty.
Description
Part Number
1
1
1
1
1
1
1
4
4
1
Muffler Canister M-7 Aluminum
Stainless Steel Slip-On Tube HARDWARE KIT
V.A.L.E.™ X-Lite Ring
8x25 Socket Head Cap Screw
8mm Flat Washer
5mm Long Handle Ball end hex key
6x14mm Socket Head Cap Screw
Split Lock Washer
Spark Arrestor (Installed) 005-167-206M
005-16701S
005-167-3
005-7-2-2
005-SH825
005-WF8
005-9-18610
005-SH614
005-WL6
005-106S
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 centerstand 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.
Muffler Inlet
X-Lite™ Ring
Slip Tube
Care & Cleaning
Keep system free of dirt and moisture. Store in a cool, dry place. Make sure vehicle is
completely cool before maintenance.
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.
Polished Aluminum Canisters: Use an aluminum or mag wheel polish to restore the
bright finish to factory spec.
V.A.L.E.™ Assembly Detail
Brushed Aluminum Canisters: Clean using a mild water based spray cleaner. Always
apply cleaner or polish with a soft, clean cloth.
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.
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 every 3,000 miles. 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.
V.A.L.E.
TM
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
2004-08 Suzuki
Z250 Quadsport
Slip-On V.A.L.E.™ Exhaust System with M-7 Canister
Part # 005-1670406V
005-1670406V
Qty.
Description
Part Number
1
1
1
1
1
1
1
4
4
1
Muffler Canister M-7 Aluminum
Stainless Steel Slip-On Tube HARDWARE KIT
V.A.L.E.™ X-Lite Ring
8x25 Socket Head Cap Screw
8mm Flat Washer
5mm Long Handle Ball end hex key
6x14mm Socket Head Cap Screw
Split Lock Washer
Spark Arrestor (Installed) 005-167-206M
005-16701S
005-167-3
005-7-2-2
005-SH825
005-WF8
005-9-18610
005-SH614
005-WL6
005-106S
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