RZR Slip-On Instructions
Installation Instructions
1. Make sure the UTV is completely cool before starting the
installation. Make sure the quad is secure on a level surface
and the wheels are chocked to prevent the quad from rolling.
-Remove 1 push pins and 4 screws per side.
2. Remove the rear bed assembly:
-Remove the rear cage (8) bolts.
-Remove the seats.
V.A.L.E.
TM
2009-10 Polaris
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
Ranger RZRS 800
V.A.L.E.™ Slip-on Exhaust System with M-7 Aluminum Canister
Part # 005-2750406V
-Remove the screws (4) behind the seats.
-Unplug lights from wire harness (1) under drivers side
of bed.
-Carefully lift bed assembly off.
Remove OEM muffler and mid-pipe (you may need to
temporarily remove heat sheild and bed rest):
- Loosen OEM clamp.
-Remove the screws (4) around the tail pipe.
IMPORTANT - PLEASE READ CAREFULLY
- Remove header joint springs. Retain for later.
- Remove mid-pipe tension spring. Retain for later.
-Remove the bolts (4) in the bed.
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. Be sure
to save all stock components for possible use later.
**This product has not been tested with all available accessories and some
items may cause excessive heat. Excessive heat may cause damage to your
vehicle. Two Brothers Racing will not be responsible for damaged parts.
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.
- Remove mid-pipe.
- Remove muffler assembly.
Installation Instructions
6. Attach the hanger bracket to the TBR muffler using the
four 6x20mm socket head cap screws and split lock
washers provided.
2009-10 Polaris
9. Re-install OEM tension springs, adjust bumper stop.
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
Ranger RZRS 800
V.A.L.E.™ Slip-on Exhaust System with M-7 Aluminum Canister
Part # 005-2750406V
Installation Instructions
3. Remove OEM heat shield from Stock mid-pipe. Un-screw bumper stop and
gasket for install on TBR mid-pipe.
7. Install TBR muffler assembly to the UTV frame using
OEM bolts and nuts.
10. Tighten muffler mount, barrel clamp, X-ring bolts.
4. Using the two OEM bolts and washers, install a lock washer as shown and
install OEM heat shield on TBR mid-pipe. Re-install bumper stop.
11. Re-install bed assembly and heat shield.
12. Re-install seats and rear cage.
13. Double check to make sure that all hardware is securely
tightened and re-check hardware after 10 hours.
8. Install barrel clamp on end of slip-tube. Install mid-pipe.
5. Attach slip-tube to TBR muffler using the two-piece X-ring and four
6x20mm socket head cap screws and split lock washers provided.
14. Before you run the quad, 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 quad and enjoy. It is normal for some white smoke to
appear the first time you start the quad. 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.
2009-10 Polaris
V.A.L.E.
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
Ranger RZRS 800
V.A.L.E.™ Slip-on Exhaust System with M-7 Aluminum Canister
Part # 005-2750406V
Care & Cleaning
Qty.
Description
Part Number
1
1
1
1
1
1
1
1
1
Muffler Canister Center
Slip-tube Mid-pipe HARDWARE KIT
X-Ring Kit
RZR Muffler Support Bracket
Barrel Clamp
TBR Sticker Kit
USFS Approved Spark Arrestor (installed)
005-27504-206M
005-27504S1
005-27504S2
005-275-3
005-7-2-3KIT
005-275B2
005-27-64MSH
015-10212
005-106S
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 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.
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