Full System (2008

Full System (2008
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.
9. Install the main collector to the 2 merge collectors
using the supplied springs and a small bead of high
temp silicon.
2. Remove side covers and seat.
V.A.L.E.
TM
2008 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
ZX-10R
V.A.L.E.™ Full Exhaust System with M-2 Canister
Part # 005-1990106V, 005-1990107V, 005-1990108V
10. Install the collectors to the headers using the supplied
springs and a small bead of high temp silicon.
3. Remove lower rear exhaust cover.
4. Remove exhaust valve cables from servo under seat.
11. Attach TBR muffler to slip-on tube using the 4 6x14mm
S.H.C.S. and lock washers provided. Leave loose for now.
*Keep servo plugged
into harness but cables
will not be used.
5. Remove OEM muffler assembly.
Parts List
Qty.
Description
1
Muffler Canister
1
4-2-1 Header Assembly
1
Slip-on Tube 1
HARDWARE KIT
1
Fender Bracket
2
Lighted License Plate Bolt
1
Turn Signals (set of 2)
6
But Splice Connectors
1
Barrel Clamp
6
80mm Swivel Hook Springs
1
Zip Ties
1
Zip Tie Tab
1
8x50mm Socket Head Flat (Black)
8
6x14mm Socket Head Cap Screw
1
5mm Long Handle Ball End Hex Wrench
4
6mm Split Lock Washer
4
6mm Flange Nut
1
High Temp Silicone
12. Slide supplied barrel clamp on end of slip tube where it
will meet TBR header assembly. Install the TBR muffler
assembly and attach using the S.H. flat bolt and OEM nut
to secure the rear muffler mount.
Part Number
Varies
005-19901H
005-19904S
005-199-3C
005-19904B
005-8504LTZ
005-88T2
005-BS1614
005-27-66MSH
005-S80
005-ZT458B
005-ZTM4
005-SHF850
005-SH614
005-9-18610
005-WL6
005-FN6
031-P22072
IMPORTANT - PLEASE READ CAREFULLY
6. Remove lower left and right fairings
7. Remove OEM header assembly (remove lower radiator
support bracket to swing radiator out for more room to
remove header nuts).
8. Install Headers 1,2,3,4 to the engine starting with 1 on
the left side of the engine as if you are sitting on the bike
facing forward. Make sure the OEM copper gasket is
between cylinder head and exhaust pipes.
13. Check alignment and tighten muffler and the 4 6x14mm
V.A.L.E.™ S.H.C.S.
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.
Continued on pg. 2
Installation Instructions
14. Tighten barrel clamp.
17. Start engine and make sure no leaks are found.
18. Re-install seats and covers.
19. Check for clearance between exhaust and all other parts and
make adjustments if needed.
V.A.L.E.
TM
2008 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
ZX-10R
20. Double check all your work.
15. Install TBR fender eliminator kit using the 4 6x14mm
S.H.C.S. and supplied nuts to rear frame.
V.A.L.E.™ Full Exhaust System with M-2 Canister
Part # 005-1990106V, 005-1990107V, 005-1990108V
21. 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. Also, remove any
plastic film from the name badge(s) and or canister clamp(s).
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.
* For best overall performance a JuiceBox (008-199) should
be used.
16. Attach turn signals and plate light bolts using the wire
splice connectors supplied to the correct wires in the
harness as shown in the Wiring Diagram.
Red
(G
Black/Yellow
l
na
Sigctor)
n
e
r
n
u n
ft T co
Le rey
Wiring Harness
WIRING DIAGRAM
Rig
(Bl ht T
ack ur
co n S
nn ign
ec
to al
ck
Bla
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.
d
Re
Bla
ck
Red
Plate Lights
r)
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.
V.A.L.E.
TM
2008 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
Polished Aluminum Canisters: Use an aluminum or mag wheel polish to restore the
bright finish to factory spec.
ZX-10R
V.A.L.E.™ Full Exhaust System with M-2 Canister
Part # 005-1990106V, 005-1990107V, 005-1990108V
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.
005-1990106V
Qty. Description
1
Muffler Canister
1
4-2-1 Header Assembly
1
Slip-on Tube 1
HARDWARE KIT
1
Fender Bracket
2
Lighted License Plate Bolt
1
Turn Signals (set of 2)
6
But Splice Connectors
1
Barrel Clamp
6
80mm Swivel Hook Springs
1
Zip Ties
1
Zip Tie Tab
1
8x50mm Socket Head Flat (Black)
8
6x14mm Socket Head Cap Screw
1
5mm Long Handle Ball End Hex Wrench
4
6mm Split Lock Washer
4
6mm Flange Nut
1
High Temp Silicone
005-1990107V
Part Number
005-199-206M
005-19901H
005-19904S
005-199-3C
005-19904B
005-8504LTZ
005-88T2
005-BS1614
005-27-66MSH
005-S80
005-ZT458B
005-ZTM4
005-SHF850
005-SH614
005-9-18610
005-WL6
005-FN6
031-P22072
Qty. Description
1
Muffler Canister
1
4-2-1 Header Assembly
1
Slip-on Tube 1
HARDWARE KIT
1
Fender Bracket
2
Lighted License Plate Bolt
1
Turn Signals (set of 2)
6
But Splice Connectors
1
Barrel Clamp
6
80mm Swivel Hook Springs
1
Zip Ties
1
Zip Tie Tab
1
8x50mm Socket Head Flat (Black)
8
6x14mm Socket Head Cap Screw
1
5mm Long Handle Ball End Hex Wrench
4
6mm Split Lock Washer
4
6mm Flange Nut
1
High Temp Silicone
005-1990108V
Part Number
005-199-207M
005-19901H
005-19904S
005-199-3C
005-19904B
005-8504LTZ
005-88T2
005-BS1614
005-27-66MSH
005-S80
005-ZT458B
005-ZTM4
005-SHF850
005-SH614
005-9-18610
005-WL6
005-FN6
031-P22072
Qty. Description
1
Muffler Canister
1
4-2-1 Header Assembly
1
Slip-on Tube 1
HARDWARE KIT
1
Fender Bracket
2
Lighted License Plate Bolt
1
Turn Signals (set of 2)
6
But Splice Connectors
1
Barrel Clamp
6
80mm Swivel Hook Springs
1
Zip Ties
1
Zip Tie Tab
1
8x50mm Socket Head Flat (Black)
8
6x14mm Socket Head Cap Screw
1
5mm Long Handle Ball End Hex Wrench
4
6mm Split Lock Washer
4
6mm Flange Nut
1
High Temp Silicone
Part Number
005-199-208M
005-19901H
005-19904S
005-199-3C
005-19904B
005-8504LTZ
005-88T2
005-BS1614
005-27-66MSH
005-S80
005-ZT458B
005-ZTM4
005-SHF850
005-SH614
005-9-18610
005-WL6
005-FN6
031-P22072
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