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. Loosen the stock muffler hardware at the rear fender. You V.A.L.E. will reuse this hardware later. 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. TM 1998-07 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 3. Take off the bolt in the middle of the header pipe (under the DR650 plastic), and remove the muffler and rear pipe. Stainless Steel Slip-on Exhaust System with M-7 Aluminum Canister Part # 005-640406 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. 4. Remove the stock muffler assembly. 5. Slide the V.A.L.E ring over s-bend tube and loosely attach to TBR muffler assembly using the 4 (four) 6x14mm socket head cap screws and split lock washers provided. Do not tighten yet. 6. Slide muffler assembly into the stock headpipe and loosely attach muffler and s-bend using O.E.M. hardware. Do not tighten yet. 7. Tighten the 4 6x14mm V.A.L.E. bolts once the muffler is aligned straight. Next, tighten the s-bend mounting bolt and then the muffler mount. The upper muffler mount is Parts List rubber mounted with a supplied spacer inside the rubber grommet. Make sure this spacer is inside the rubber. Qty. Description Part Number 1 1 1 1 1 1 1 1 DR650 Muffler Canister M-7 Aluminum DR650 Stainless Steel S-Bend Tube Spacer (Installed) Rubber Grommet (Installed) HARDWARE KIT X-Ring Kit TBR Sticker Kit Spark Arrestor (Installed) 005-64-206M 005-6404S 005-64-24 005-9307K62 005-64-3 005-7-2-3KIT 015-10212 005-106S 8. 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 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. should fix it. After 50 to 100 miles, recheck all fasteners for tightness. 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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