Installation Instructions 1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on a centerstand or ideally a service lift. V.A.L.E. 2004-05 Kawasaki 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 TM ZX-10R 2. Loosen the clamp holding the muffler to the header. This clamp is by the right, rider peg. 3. Remove hardware holding the muffler to the passenger footpeg. 4. Remove muffler with a twisting motion. V.A.L.E.™ Slip-on Exhaust System with M-2 Canister Part # 005-1110406V, 005-1110407V, 005-1110408V 5. Join the V.A.L.E.™ cap with the end of the M2 muffler using the supplied 6x14mm screws. Be sure to use the included threadlock on all 4 of the screws. Loosely tighten all four screws. Keep the screws loose enough so that the tube can rotate back and forth inside the V.A.L.E.™ Cap. 8. Tighten mounting hardware in the following order: 1. Muffler clamp 2. V.A.L.E.™ inlet (torque to 7 ft. lbs.) 3. T-Bolt clamp 9. A long 5mm ball-end allen wrench will help with accessing the bolts on the V.A.L.E.™ inlet. Check for proper clearances and alignment and adjust muffler accordingly. 10.Check muffler position and alignment. When it is correct, tighten the 4 6x14mm socket head cap screws and the barrel clamp. 11.Double check your work. 12.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. Muffler Inlet X-Lite™ Ring Slip Tube Parts List Care & Cleaning Qty. Description Part Number 1 1 1 1 1 1 1 1 1 Varies Varies 005-11104N 005-111-3 005-7-2-3KIT 005-27-64MSH 005-S-18 005-SH855 015-10212 M-2 Muffler Canister Muffler Clamp Slip-On Tube HARDWARE KIT X-Ring Kit 64mm Barrel Clamp 18mm Aluminum Spacer 8x55mm Socket Head Cap Screw Sticker Kit Care & Cleaning Keep system free of dirt and moisture. Store in a cool, dry place. Make sure vehicle is completely cool before maintenance. V.A.L.E.™ Assembly Detail 6. Install barrel clamp loosely on connector tube. 7. Install entire assembly onto the header by gently turning it into position. Slide the muffler clamp onto the muffler. Now slide the 18mm aluminum spacer behind the muffler clamp and secure using the 8mm x 55mm bolt and stock nut. Tighten finger tight. 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. 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 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. 18mm Spacer 8x55mm Bolt 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. Fron t 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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