Full System (2011

Full System (2011
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.
2.
Remove both main and passenger seats.
6.
Install supplied servo stop in place of servo
wheel and reinstall servo box in orginal mounting
position.
7.
Remove o2 sensor from header.
Suzuki
GSX-R600 / 750
V.A.L.E.™ Full Exhaust System with M-2 Exhaust Canister
Part # 005-3040106V, 005-3040107V, 005-3040108V
Qty. Description
Part Number
1
M-2 Muffler Canister
1
Canister Clamp with Rubber Liner
1
Slip-on tube
1
Header assembly
1
HARDWARE KIT
1
Adaptor Kit
2
X-Ring (half)
1
64mm Barrel Clamp
1
8mm Flange Nut
1
Servo Stop
4
6x20mm Socket Head Cap Screws
4
6mm Split Lock Washer
1
T20 Torx Hex Key
1
5mm Ball End Hex Key
1
TBR Sticker Kit
Varies
Varies
005-30401S
005-30401H
005-304-3C
3.
Remove fuel tank.
8.
Remove OEM muffler assembly.
4.
Remove left and right fairings.
9.
Remove header assembly including butterfly
cables, loosen radiator bolts for better access.
5.
Remove servo box located under fuel tank to
access the butterfly cables. Remove servo wheel by
holding in place using a suitable tool to remove bolt
without causing damage to servo.
005-92-22KIT
005-7-2-4
005-27-64MSH
005-FN8
005-125-05-01
005-SH620
005-WL6
005-9-15820
005-9-18610
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 Information
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. Not tested for use
Installation Instructions
10. Install TBR assembly using OEM hardware.
12. Loosely attach muffler to bike using the OEM
bolt and nut and install muffler clamp to inside of
passenger footpeg.
Suzuki
GSX-R600 / 750
V.A.L.E.™ Full Exhaust System with M-2 Exhaust Canister
Part # 005-3040106V, 005-3040107V, 005-3040108V
13. Attach mid-pipe support bracket using OEM bolt
and supplied 8mm nut. Re-install o2 sensor.
11. Attach muffler to TBR slip system using the
supplied X-ring, 6x20mm socket head cap screws
and lock washers that are provided, leave loose for
now. Slide rubber lined muffler clamp and barrel
clamp on and install to bike.
14. Check for clearance and alignment, then tighten all
the bolts in this order: X-ring bolts, muffler mount,
support bracket, and finally barrel clamp. Remove
metal inner sleeves from rubber grommits from
OEM header mounts.
15. Re-install fairings, fuel tank and seats.
Qty. Description
Part Number
1
M-2 Muffler Canister
1
Canister Clamp with Rubber Liner
1
Slip-on tube
1
Header assembly
1
HARDWARE KIT
1
Adaptor Kit
2
X-Ring (half)
1
64mm Barrel Clamp
1
8mm Flange Nut
1
Servo Stop
4
6x20mm Socket Head Cap Screws
4
6mm Split Lock Washer
1
T20 Torx Hex Key
1
5mm Ball End Hex Key
1
TBR Sticker Kit
Varies
Varies
005-30401S
005-30401H
005-304-3C
005-92-22KIT
005-7-2-4
005-27-64MSH
005-FN8
005-125-05-01
005-SH620
005-WL6
005-9-15820
005-9-18610
015-10212
16. 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. 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.
Care & Cleaning / Warranty Information
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.
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.
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