Installation Instructions 1. Make sure the quad is completely cool before starting the installation. Make sure the quad is secure on a level surface and the wheels are chocked to prevent the quad from rolling. 4. Remove exhaust pipe joint springs(2) above rear right wheel. 2. Remove the seats. V.A.L.E. TM 2011 Polaris 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 Ranger RZR 900 XP V.A.L.E.™ Dual Full Exhaust System with M-7 Aluminum Canister Part # 005-3090106DV 5. Remove 6 header flange bolts and remove OEM header system. 3. Tilt the panel forward behind the seats to access the header pipes. 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. Be sure to save all stock components for possible use later. **This product has not been tested with all available accessories and some items may cause excessive heat. Excessive heat may cause damage to your vehicle. Two Brothers Racing will not be responsible for damaged parts. 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. 6. Remove muffler retaining springs(2) and remove OEM muffler assembly. Installation Instructions 9. Re-route the clear hose from behind the driver seat to go under the frame bar. 2011 Polaris 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 Ranger RZR 900 XP V.A.L.E.™ Dual Full Exhaust System with M-7 Aluminum Canister Part # 005-3090106DV Installation Instructions 11. Install header collars and flanges with spring hook ears on top as shown. 7. Remove OEM bolts above left and right wheel wells as shown in photo. 10. Using supplied 6x14mm bolt and nut install rubber liner to retaining bracket and mount as shown behind drivers seat. Loosely wrap hoses and bracket with supplied ziptie, make sure you have rubber side down on bracket. 8. Install new supplied mounting bracket in both wheel wells using supplied 8x25mm bolts and rear bolts will use supplied 8mm nuts. 12. Install headers using supplied spring hooks as shown, tighter radius header installs on passanger side. V.A.L.E. 2011 Polaris V a r i a b l e A x i s L o c k i n g Ranger RZR 900 XP V.A.L.E.™ Dual Full Exhaust System with M-7 Aluminum Canister Part # 005-3090106DV E x h a u s t Installation Instructions 13. Loosely attach slip tubes to TBR exhaust canisters using the supplied 6x20mm bolts, washers and X-rings as shown. The shorter tube goes on canister on the passenger side. 15. Tighten X-ring bolts. 005-3090106DV 16. Replace panel and seats. 17. Double check to make sure that all hardware is securely tightened and re-check hardware after every 10 hours. 14. Install TBR muffler assemblys to header tubes on both sides and secure in place with supplied 8x25mm bolts with lock nuts to mounting bracket. Qty. Description Part Number 1 1 1 1 1 1 1 1 2 2 2 8 8 4 6 1 1 8 1 1 1 1 2 Muffler Canister Left Muffler Canister Right Header Kit HARDWARE KIT Muffler Mounting Bracket - Left Muffler Mounting Bracket - Right Retaining Bracket High Temp Rubber Liner Header Collar Header Flanges X-Ring (half) 6x20mm Socket Head Cap Screw M6 Split Lock Washer 80mm Spring 8x1.25mm Locking Flange Nut 6x14mm Socket Head Cap Screw 6mm Flange Nut 8x25mm Socket Head Cap Screw Zip tie 5mm Long Handle Ball end hex key T20 Torx Screw Wrench TBR Sticker Kit USFS Approved Spark Arrestor (installed) 005-309-206ML 005-309-206MR 005-30901H 005-309-3C 005-309-BL 005-309-BR 005-309-B 005-LC 005-309-15S 005-309-17 005-7-2-2 005-SH620 005-WL6 005-S80 005-FNL8 005-SH614 005-FN6 005-SH825 005-ZTB 005-9-18610 005-9-15820 015-10212 005-106S 18. Before you run the quad, 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 quad and enjoy. It is normal for some white smoke to appear the first time you start the quad. 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. 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. 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 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.
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