Installation instructions

Installation instructions
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.
5. Remove bottom fairings by removing six bolts.
2. Remove the OEM muffler assembly.
Kawasaki
NINJA 300
Full Exhaust System with M-2 Canister
Part # 005-32701
6. Remove OEM header and take off header gaskets for
use with TBR header.
3. Remove clip and bolt from passenger foot peg,
replace with 6x45mm bolt.
7. Install stock gaskets on TBR full system and mount
to bike.
4. Install Muffler bracket using previously installed
6x45mm bolt and OEM muffler bolt. Use supplied
6mm Flange nut to secure in place.
8. Install mid-pipe to bike using 57mm barrel clamp and
8x16mm flange bolt and nut.
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.
(Continued on page 2)
Installation Instructions
9. Attach the TBR slip-on tube to muffler using the 4
6x20mm socket head cap screws and 6mm split
washers provided. Leave loose for now.
14.Check muffler position and alignment. When it is
correct, tighten the 4 6x20mm socket head cap screws,
the barrel clamp, and muffler clamp.
Kawasaki
NINJA 300
Muffler Inlet
Full Exhaust System with M-2 Canister
Part # 005-32701
X-Lite™ Ring
15.Re-install lower fairing.
16.Double check your work.
Slip Tube
V.A.L.E.™ Assembly Detail
10.Slide 58mm barrel clamp on the end of the slip-on tube.
17.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. 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.
11.
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.
Qty. Description
Part Number
1
M-2 Muffler Canister
1
Slip-On Tube
1
HARDWARE KIT
1
57mm Barrel Clamp
1
58mm Barrel Clamp
1
8x20mm Socket Head Flat Bolt
1
Counter Sunk Aluminum Washer
1
Muffler Bracket
2
X-Lite Retaining Ring Half
2
Flange Nut 8mm
1
6x45mm Socket Head Cap Screw
1
6mm Flange Nut
1
T20 Torx Hex Key
1
5mm Long Handle Ball end hex key
1
8x16mm Flange Bolt
4
6x20mm Socket Head Cap Screw
4
6mm Split Washers
1
TBR Sticker Kit
Varies
005-32701S
005-327-3
005-27-57MSH
005-27-58MSH
005-SHF820
005-WA8
005-327-B
005-7-2-3
005-FN8
005-SH645
005-FN6
005-9-15820
005-9-18610
005-SH816
005-SH620
005-WL6
015-10212
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.
12.Install the TBR muffler assembly to the motorcycle
using the supplied 8x20mm socket head flat bolt and
dished washer and 8mm flange nut.
13.
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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