Installation Instructions 1. Make sure the quad 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.™ Triple Full Exhaust System with M-7 Aluminum Canister Part # 005-2750106TV -Remove the screws (4) behind the seats. -Unplug lights from wire harness (1) under drivers side of bed. -Carefully lift bed assembly off. 3. 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. - Remove mid-pipe tension springs. -Remove the bolts (4) in the bed and 2 tiedown hooks. 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. Remove OEM heat shield and turn 180 0. Re-install on TBR headerusing the 2 OEM bolts and washers. 2009-10 Polaris 9. Install TBR header to cylinder head using the supplied header gasket (if the stock gasket is un-damanged you may use that instead) and OEM mounting bolts at header flange. Use supplied 8x20mm socket head cap screw to secure header assembly to cylinder head on side mount. 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.™ Triple Full Exhaust System with M-7 Aluminum Canister Part # 005-2750106TV Installation Instructions 4. Remove OEM header assembly, you may need to remove stabilizer bracket to access header mounting bolts. 7. Attach the hanger bracket to the TBR center muffler using the 4 (four) 6x14mm socket head cap screws and split lock washers provided. 5. Install heat shield bracket to TBR header using the supplied hose clamps. 8. Remove rear frame bolts/nuts to install muffler stabilizer mount on top of frame rail and center muffler with mounting bracket attached under frame rail. The stock hardware is re-used. 10. Attach TBR triple collector with clips as shown in photo. Installation Instructions 12. Mount supplied muffler mounting brackets to bed support using the supplied 8x35mm socket head cap screws and lock washers provided, leave loose for now. 2009-10 Polaris 16. Tighten X-ring bolts. Tighten muffler mounting bolts on all 3 mufflers. 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.™ Triple Full Exhaust System with M-7 Aluminum Canister Part # 005-2750106TV 17. Re-install sway bar bolts. 18. Re-install bed assembly. Installation Instructions 19. Tighten muffler mounting bracket bolts, and billet muffler mounting bracket. 11. Locate slip-fit joint exhaust pipes and attach right side and center pipe with springs. Install left side exhaust pipe and attach with spring. The left side exhaust pipe uses OEM tension stop(remove from OEM exhaust and install on TBR exhaust). 13. Attach muffler to muffler bracket using the supplied 8x45mm socket head cap screws with lock nuts, leave loose for now. 20. Re-install seats and rear cage. 21. Double check to make sure that all hardware is securely tightened and re-check hardware after every 10 hours. 14. Attach TBR muffler to their exhaust pipes using the supplied 6x14mm socket head cap screws and lock washers with thread locker using the supplied 2pc. X-Ring, leave loose for now. 15. Make any adjustments to collector or exhaust pipes if needed by rotation of triple collector. Install OEM tension springs on left and right side exhaust pipes. 22. 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.™ Triple Full Exhaust System with M-7 Aluminum Canister Part # 005-2750106TV 005-2750106TV Qty. Description Part Number 1 1 1 1 1 6 16 16 3 1 3 1 2 2 1 1 2 4 1 4 2 1 1 1 1 3 3 Muffler Canister Left Muffler Canister Center Muffler Canister Right Header Kit HARDWARE KIT X-Ring (half) 6x14mm Socket Head Cap Screw M6 Split Lock Washer 80mm Hook Spring Heat Shield Bracket Hose Clamps Header Gasket RZR Billet Muffler Mounting Bracket RZR Billet Muffler Mounting Lower Bracket RZR Center Muffler Support Bracket RZR Hanging Support Bracket 8x1.25mm Flange Nut M8 Lock Washers 8x20mm Socket Head Cap Screw 8x35mm Socket Head Cap Screw 8x45mm Socket Head Cap Screw Permatex Thread Lock 5mm Long Handle Ball end hex key T20 Torx Screw Wrench TBR Sticker Kit USFS Approved Spark Arrestor (installed) P1X Powertip (installed) 005-275-206ML 005-275-206MC 005-275-206MR 005-27501HK 005-275-3C 005-7-2-3 005-SH614 005-WL6 005-S80 005-275-HSB 005-HC-64024 005-275G 005-275-21B 005-275-21BU 005-275B2 005-275B 005-FNL8 005-WL8 005-SH820 005-SH835 006-SH845 031-P09179 005-9-18610 005-9-15820 015-10212 005-106S 005-P1X 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. 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.
* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project