Full System (2006
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.
12. Securely tighten the 4 (four) 6 x 14mm socket head cap
screws of the V.A.L.E. assembly with the supplied 5mm hex
wrench. (See V.A.L.E.™ Assembly Detail)
2.Remove right side panel.
V.A.L.E.
TM
2006-08 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
KX250F
11.Making sure that the V.A.L.E. assembly is oriented correctly,
securely tighten lower muffler mounting bolt.
3.Remove upper muffler mounting bolt.
13. Securely tighten the upper muffler mounting bolt.
4.Remove lower muffler mounting bolt.
14. Securely tighten the two header nuts.
5.Loosen muffler joint clamp.
15. Reinstall side panel with original hardware.
Complete Exhaust System with M-7 Canister
Part # 005-1340106V / 005-1340107V / 005-1340108V
6.Remove muffler assembly.
16. Double check to make sure that all hardware is tightened
7. Remove head pipe flange nuts.
8.Remove head pipe.
9.Install the new Two Brothers Racing head pipe making sure
that the original copper gasket is between the cylinder and
head pipe. Loosely install 2 (two) OEM head pipe nuts to
hold header in place.
10. Assemble the V.A.L.E. unit to the muffler canister: Use the
4 (four) 6 x 14mm socket head cap screws and split lock
washers to loosely attach the X-Lite™ ring to muffler inlet.
(See V.A.L.E. Assembly Detail below)
11.Attach header assembly to the motorcycle. Slip the s-bend
tube into the head pipe. Secure muffler canister to the bike
using OEM hardware. The OEM muffler joint clamp is not
used with the Two Brothers Full Race System.
Parts List
Muffler Inlet
Qty.
Description
Part Number
1
RMZ/KX250F Muffler Canister M-7
1
KX250F S-Bend for Complete System
1
KX250F Header
1
HARDWARE KIT
2
X-Ring (half)
1
5mm Long Handle Ball end hex key
4
Split Lock Washer
4
6x14mm Socket Head Cap Screw
1
TBR Sticker Kit
X-Lite™ Ring
Varies
Varies
Varies
005-134-3C
005-7-2-3
005-9-18610
005-WL6
005-SH614
015-10212
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.
Slip Tube
17.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.
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
2006-08 Kawasaki
KX250F
Complete Exhaust System with M-7 Canister
005-1340106V
Qty. Description
1
RMZ/KX250F (04-06 KX) (04-06 RMZ)
Muffler Canister M-7 Brushed Aluminum
1
KX250F Stainless Steel S-Bend for Complete
1
KX250F Stainless Steel Header
1
HARDWARE KIT
2
X-Ring (half)
1
5mm Long Handle Ball end hex key
4
Split Lock Washer
4
6x14mm Socket Head Cap Screw
1
TBR Sticker Kit
1
Spark Arrestor (Installed) 005-1340107V
Part Number
005-120-206M
005-13401SC
005-13401H
005-134-3C
005-7-2-3
005-9-18610
005-WL6
005-SH614
015-10212
005-106S
Qty. Description
1
RMZ/KX250F (04-06 KX) (04-06 RMZ)
Muffler Canister M-7 Carbon Fiber
1
KX250F Stainless Steel S-Bend for Complete
1
KX250F Stainless Steel Header
1
HARDWARE KIT
2
X-Ring (half)
1
5mm Long Handle Ball end hex key
4
Split Lock Washer
4
6x14mm Socket Head Cap Screw
1
TBR Sticker Kit
Part Number
005-120-207M
005-13401SC
005-13401H
005-134-3C
005-7-2-3
005-9-18610
005-WL6
005-SH614
015-10212
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