Installation Instructions 1. 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. 2. Remove the passenger footpegs (left and right). V.A.L.E. TM Suzuki 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 DL1000 V-STROM 3. Loosen the clamps that holds the muffler connector pipes to the headers. 4. Remove the hardware that holds the stock mufflers to the bike. Be sure to remove the stock exhaust gaskets from the header as you will NOT reuse it. 5. Assemble the V.A.L.E.™ assembly by attaching the muffler to the X-Lite V.A.L.E.™ retaining ring and slip-on tube using the 4 6x14mm S.H.C.S. and lock washers provided. Keep loose for now. Muffler Inlet X-Lite™ Ring Slip Tube V.A.L.E.™ Assembly Detail 6. Place a bead of the hi-temp sealant on the outside edge of the header that goes into the s-bends. Slide the S-bend connector pipes onto the end of the headers, using the barrel clamps to attach it to the headers. Leave loose for now. Wipe off the excess sealant that will squeeze out. Parts List Qty. Description Part Number 1 1 2 1 1 1 2 2 2 2 2 1 Muffler Canister (Left Side) Muffler Canister (Right Side) Muffler Canister Clamps V.A.L.E.™ Slip Tube (Left) V.A.L.E.™ Slip Tube (Right) HARDWARE KIT X-Ring Kit 8x70 Socket Head Cap Screw 8mm Flat Washer 26mm Aluminum Spacer Barrel Clamps Permatex Ultra Black Gasket Maker Varies Varies Varies 005-4804NLV 005-4804NRV 005-48-3 005-7-2-3KIT 005-SH870 005-WF8 005-S-26 005-27-61MSH 031-P22072 7. Carefully slide the muffler clamps over the mufflers. You may need to twist and turn the S-bend a little to get it in the right place. Locate both tabs of the canister clamp outside of the spacers. Use the hardware provided to secure it to the stock mounting location. Leave loose for now. 8. Make sure everything is aligned and tighten all hardware. 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. 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. IMPORTANT - PLEASE READ CAREFULLY We recommend that this performance part be installed by a qualified 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. 9. Reinstall the passenger footpeg brackets WITHOUT the heatshields attached. 10. Double check to make sure that all hardware is tightened. 11. Before you run the bike, clean off all fingerprints and dirt, as any oily residue will etch the metal and become permanent when the system gets hot. Also, remove any plastic film from the name badge(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. 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.
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