S1R Full System (2009

S1R Full System (2009
Installation Instructions
Kawasaki
ZX-636
1.
Make sure the bike is completely cool before starting
the installation. Make sure the bike is secure on a center
stand or ideally a service lift.
2.
Remove side covers and seat.
8.
Remove lower left and right fairings.
9.
Remove front header cover.
Full Exhaust System
Part # 005-3860105-S1
3.
Remove rear passenger seat.
4.
Remove OEM rear fender. You will reuse the fender bolts.
10. Remove header pipes.
5.
Remove rear exhaust cover.
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.
11. Using the OEM copper gasket between header collar and
cylinder head. Install TBR header using OEM bolts.
Polished Aluminum Canisters: Use an aluminum or mag wheel polish to restore the bright finish to factory spec.
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.
6.
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.
Remove exhaust valve cables from servo under seat. Use
a wrench to hold server wheel in place or internal gears
may break.
Repack all road canisters at the first signs of packing material deterioration. Part #005-10038
12. Remove lower rear set mounting bolt and replace with
supplied 8x40mm socket head cap screw.
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.
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 center stand
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.
*Keep servo plugged
into harness but cables
will not be used.
7.
Remove OEM muffler assembly.
Installation Instructions
13. Attach the supplied mounting bracket to the inside of
frame and secure in place with the supplied 8mm flange
nut. Bracket should be installed as shown in picture.
Kawasaki
ZX-636
18. Tighten barrel clamp.
19. Install TBR fender eliminator kit using the original bolts
and supplied nuts, the nuts will be inside the bike under
seat.
20. Attach turn signals and plate light bolts using the wire
splice connectors supplied to the correct wires in the
harness as shown in the Wiring Diagram.
Full Exhaust System
Part # 005-3860105-S1
21. Re-install seats and covers.
22. Double check all your work.
14. Apply a thin layer of anti-seize to slip tube outlet and
attach TBR muffler using supplied hook springs. Install
barrel clamp onto slip tube.
23. 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. Also,
remove any plastic film from the name badge(s) and or
canister clamp(s). 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.
15. Install rubber lined muffler clamp over canister. Mount
the slip-tube using the supplied 10mm nut and OEM
bolt.
16. Attach the TBR muffler assembly using the flange bolt
and nut to secure the muffler in place.
Part Number
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Plate Lights
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Varies
Varies
005-24101H
005-38601S
005-27-63MSH
005-241-B
005-19904B
005-8504LT2
005-88T2
005-BS1614
005-ZT458B
005-ZTM4
005-SH840
005-FN6
005-FB816
005-FN8
005-NN11
005-S45
005-SP
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Description
S1R Canister
Muffler Clamp
Header Slip Tube
Barrel Clamp
Muffler Bracket
Fender Bracket
Lighted License Plate Bolt
Turn Signals (set of 2)
Butt Splice Connectors
Zip Tie
Zip Tie Tab
8x40mm Socket Head Cap Screw
6mm Flange Nut
8x16mm Flange Bolt
8mm Flange Nut
10mm Nut
45mm Spring
Spring Puller
Red
Qty.
1
1
1
1
1
1
1
2
1
6
1
1
1
4
1
2
1
2
1
Wiring Harness
17. Check alignment and tighten muffler.
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