Full System (2008
Installation Instructions
1.
Make sure the bike is completely cool before starting the
installation. Make sure the bike is secure on a rear stand or
ideally a service lift.
2.
Remove lower right fairing from the motorcycle.
8.
Remove the noise reduction valve servo bracket from the
frame.
9.
Remove servo by pulling out from the right side of the
motorcycle and disconnect the cables. Disregard cables.
Yamaha R6
Complete Exhaust System
Part # 005-4060105-S1
3.
IMPORTANT - PLEASE READ CAREFULLY
Two Brothers Racing products are intended for closed course competition purposes
only.
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.
Remove muffler inlet cover from front of muffler to expose
exhaust valve cables (noise reduction valve).
4.
Remove cables from muffler and cable clamp from right
side rear set assembly.
5.
Remove muffler joint clamp and muffler mounting bolt.
6.
Remove muffler assembly.
7.
Remove bracket holding the brake reservoir to the frame.
Care & Cleaning / Warranty
Care & Cleaning
Keep system free of dirt and moisture. Store in a cool, dry place. For cleaning use a mild spray cleaner.
Always apply cleaner or polish with a soft, clean cloth.
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.
Carbon Fiber Mufflers: 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 (TBR part # 005-10038) that include new rivets and repack material as well as a drill bit (#30),
making it easy to do yourself. Also, NEVER dyno test your bike with carbon fiber mufflers installed - the
intense heat and lack of cooling air can quickly cause the CF material to burn. Two Brothers Racing does
not provide a warranty for burned carbon fiber.
Aluminum Mufflers: Use an aluminum or mag wheel polish such as Mother’s to restore the bright finish to
factory spec.
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.
10. Remount the servo without the cables. Make sure servo is
plugged into wiring harness. This step is necessary in order to
keep an error code from being displayed on the LCD screen.
11. Reinstall the brake reservoir.
12. Remove the stock header exhaust port nuts (8 nuts total) in
order to remove the stock headers.
13. Allow the head pipe assembly to swivel downward.
Installation Instructions
14. Remove both 8mm allen bolts and the O2 sensor plug from
rear of head pipe assembly, making sure to support it with
your hand from underneath.
Yamaha R6
15. Remove the head pipe assembly from the bike.
Complete Exhaust System
Part # 005-4060105-S1
16. Attach TBR headers to exhaust ports with the stock flange
nuts. Make sure to keep OEM copper gaskets between the
head pipe and cylinder head.
17. Detach right side rear set from frame to gain access to peg
bolt. Remove bolt and install TBR muffler bracket as shown.
Some adjustment may be required for proper alignment.
Qty.Description
Part Number
1
1
1
1
1
1
1
1
1
2
1
1
8” S1R
005-40601H
005-40601S
005-2C-S1
005-2C-S1-C
005-406-B
005-FN8
005-27-66MSH
005-SH820
005-S45
005-SP
031-P09175
Muffler Canister Header
Slip-Tube
Muffler Clamp
Muffler Clamp Liner
Bracket
8mm Flange Nut
66mm Barrel Clamp
8x20mm Socket Head Cap Screw
Spring
Spring Puller
Permatex Anti-Seize
19. Apply a thin layer of anti-seize to slip tube and attach to S1R
using supplied hook springs.
20. Slide S1R clamp over muffler and barrel clamp onto slip
tube inlet. Attach to TBR head tube collector.
21. Adjust for proper fit and alignment then attach S1R clamp to
bracket with supplied 8x16mm socket head bolt and flange
nut. Clamp goes to inner inside of bracket.
22. Apply anti-seize to O2 sensor threads and install onto TBR
slip tube.
23. Tighten barrel clamp.
24. Double check your work and make sure all hardware is
securely tightened.
18. Re-attach rear set to frame.
25. 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.
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