Slip-On System (2004
Installation Instructions
Make sure the bike is completely cool before starting the
installation. Make sure the bike is secure on the sidestand or
ideally a rear service stand.
V.A.L.E.
2004-05 Kawasaki KX250F &
2004-06 Suzuki RMZ250
1. Remove right rear plastic panel to expose existing
exhaust system.
14. 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. After
50 to 100 miles, recheck all fasteners for tightness.
2. Remove bolt connecting existing exhaust canister to
frame.
Slip-on Exhaust System with M-7 Canister
Part # 005-1200406V / 005-1200407V
3. Remove bolt at junction of existing connector &
headpipe.
Muffler Inlet
X-Lite™ Ring
4. Remove old muffler & connector tube.
Slip Tube
5. Loosely attach the V.A.L.E.™ muffler to the stainless steel
s-bend tube using the four supplied 6x14mm socket head
cap screws and split lock washers. Leave bolts loose for
now.
8. Insert the V.A.L.E.™ assembly in from the rear of the bike.
Carefully rotate the pipe into position and slide it onto the
header.
7. Carefully rotate muffler assembly to align the 8x25mm
bolt with the mounting hole on the frame, insert the bolt
and loosely tighten.
Parts List
Qty.
Description
Part Number
1
M-7 Muffler Canister 1
Stainless Steel S-Bend Tube 1
HARDWARE KIT
1
Side Panel Spacer
4 6x14mm Socket Head Cap Screw 1 8x25mm Flange Bolt 1 5mm Long Handle Ball End Hex Key 4 Split Lock Washer 2 TBR Script Logo Yellow Decal 4” 1
Spark Arrestor (aluminum canister only) Varies
005-12001S
005-120-3
005-S-13
005-SH614
005-FB825
005-9-18610
005-WL6
015-10208-A
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 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.
8. Attach lower s-bend
hardare.
mount to subframe using OEM
9. Once the muffler is aligned tighten the four 6mm x 14mm
V.A.L.E.™ screws with the supplied ball end hex key.
V.A.L.E.™ Assembly Detail
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.
10. Tighten rear muffler top mount
11. Check your work and clean all fingerprints.
12. Re-install the plastic panel, and anything else that you
may have loosened or removed in order to install the
exhaust system.
13. Double check to make sure everything is aligned and
tighten all hardware.
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
2004-05 Kawasaki KX250F &
2004-06 Suzuki RMZ250
Slip-on Exhaust System with M-7 Canister
Part # 005-1200406V / 005-1200407V
Qty.
Part Number
Qty.
1
M-7 Muffler Canister 1
Stainless Steel S-Bend Tube 1
HARDWARE KIT
1
Side Panel Spacer
4 6x14mm Socket Head Cap Screw 1 8x25mm Flange Bolt 1 5mm Long Handle Ball End Hex Key 4 Split Lock Washer 2 TBR Script Logo Yellow Decal 4” Description
005-120-206M
005-12001S
005-120-3
005-S-13
005-SH614
005-FB825
005-9-18610
005-WL6
015-10208-A
1
M-7 Muffler Canister 1
Stainless Steel S-Bend Tube 1
HARDWARE KIT
1
Side Panel Spacer
4 6x14mm Socket Head Cap Screw 1 8x25mm Flange Bolt 1 5mm Long Handle Ball End Hex Key 4 Split Lock Washer 2 TBR Script Logo Yellow Decal 4” 005-120-207M
005-12001S
005-120-3
005-S-13
005-SH614
005-FB825
005-9-18610
005-WL6
015-10208-A
1
005-106S
1
005-106S
Spark Arrestor (aluminum canister only) Description
Spark Arrestor (aluminum canister only) Part Number
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