Brocks Performance CT Single Full System 1 User Manual

DOCUMENT ID 994445

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Installation Instructions for the

BMW S 1000 RR (2010-11) CT Single Exhaust System

CHECK PACKAGE CONTENTS

1. One (1) Left Side Header (Cylinders 1 & 2)

2. One (1) Right Side Header (Cylinders 3 & 4)

3. One (1) Collector (Y-Pipe)

4. One (1) Mid-Pipe

5. One (1) CT Single Muffler

6. One (1) Package Containing Flanges, Collars, Springs, Spring
Puller, Bracket and Hardware

7. One (1) Instruction Package

If any parts are missing, contact Brock’s Performance Products.

Brock’s Performance CT Single

***PAIR BLOCK OFF MUST BE PERFORMED TO PREVENT PREMATURE EXHAUST FAILURE***

www.brocksperformance.com/Instructions/S1000RR/994471.pdf

PRE-ASSEMBLE HEADERS AND COLLECTOR TO ENSURE PROPER FIT BETWEEN ALL PARTS

Brock’s Performance carefully inspects each
system prior to shipping, we recommend that
you test fit your system prior to installation.
Apply WD-40 to the joints to ease assembly,
adjustment, and/or disassembly.

REMOVE BODYWORK

Consult a factory service manual for additional information. To remove
the left lower fairing, remove the five (5) mounting bolts from the
inside and bottom of the lower fairing pointed at by the red arrows.
Remove the seven (7) mounting bolts from the outside of the lower
fairing in the red circles. Remove the one (1) plastic fastener in the
green circle by unscrewing the center pin then pulling the fastener out.
Pull out on the fairing to detach from the push pin pointed at by the
green arrow. Pull the fairing out just far enough to access the turn
signal wire located on the top of the radiator mount and unplug. The
left lower fairing can now be removed.

Brock’s Performance Products • 4064 East Patterson Road • Dayton, OH 45430 • Phone: [phone] • Fax: [phone]

DOCUMENT ID 994445

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To remove the right lower fairing, remove the four (4) mounting bolts
from the inside and bottom of the lower fairing pointed at by the red
arrows. Remove the seven (7) mounting bolts from the outside of the
lower fairing in the red circles. Remove the one (1) plastic fastener in
the green circle by unscrewing the center pin then pulling the fastener
out. Pull out on the fairing to detach from the push pin pointed at by
the green arrow. Pull the fairing out just far enough to access the turn
signal wire located on the top of the radiator mount and unplug. The
right lower fairing can now be removed.

To remove the seat, loosen the two (2) mounting screws under the rear edge
of the seat pointed at by the red arrows. Pull the edge of the seat foam
forward to expose the screws. Lift the rear of the seat to clear the tail and
slide the seat rearward to remove.

To remove the fuel tank trim, remove the seven (7) mounting bolts from the
upper tank cover and lift off. Remove the three (3) mounting bolts from each side trim panel. The side trim panel slides
forward to remove. The red circles show the mounting bolts that need to be removed.

REMOVE THE MUFFLER

Loosen the clamp bolt for the muffler, only needs to be loosened not removed. Remove the mounting bolt to the foot
control bracket. Apply a slight twisting force while pulling on the muffler to slide it from the catalytic converter. Slide the
heat shield from the catalytic converter.

REMOVE THE HEAD PIPES / CATALYTIC CONVERTER

The headers and catalytic converter is one (1) piece on the S 1000 RR. Disconnect the O2 sensor cables, the connectors
are on the left and right sides of the cylinder head. Remove the cable from the front exhaust valve servo motor, located
on the left side above the radiator. Pull the cable out of the clip and remove the end from the pulley, the servo motors
must remain installed and plugged in. To remove the cables for the rear exhaust valve servo motor, remove the seat, left
and right side fuel tank trim panels. The servo motor is located above the shock absorber and the cables can be reached
from the sides, pull the cables from the clips and remove the ends from the pulley.

The exhaust valve servo motors

cannot be removed or unplugged, this would create an error code in the ECU.

Remove the radiator / oil cooler mounting
bracket. Remove the “E” clips and washers from the bottom of the radiator and bottom of the oil cooler. Remove the bolt
securing the bracket to the crankcase. Remove the two (2) bolts securing the oil cooler to the radiator,

do not remove the

oil lines and

be very careful to not damage the oil cooler or its fins

. You can gently push the radiator forward to make
room for the removal of the headers. Remove all eight (8) of the mounting nuts holding the four primaries to the head.
Remove the two (2) bolts mounting the catalytic converter to the frame and the four (4) bolts securing the brackets to
the catalytic converter. Drop the catalytic converter down to clear the frame, move the system forward to disengage the
primary pipes from the cylinder head and remove from the bike.

Be careful not to hit the flanges of the pipes on the

radiator or oil cooler,

place a piece of cardboard over the radiator and oil cooler to protect them.

DOCUMENT ID 994445

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Check to make sure the exhaust gaskets are still in the head, do not remove, you will reuse these.

INSTALL FLANGES

Insert the flange collars into the flanges. Using the eight (8) 12-point nuts from the original flanges, attach the flanges
with the collars against the gaskets in the cylinder head and aligned as shown. Make sure flanges are flat to the gaskets
and tighten flanges to 10-15 ft-lbs to promote a proper seal.

INSTALL HEAD PIPES

If you are not using a Power Commander, remove the stock O2 sensors from
the stock headers, apply anti-seize to the threads, install in the bungs of the
primary header pipes, and tighten. If you are using a Power Commander,
apply anti-seize to the threads of the supplied plugs, insert with the supplied
copper gaskets into the bungs, and tighten. Insert one (1) spring into each
hole of the flanges. Install the head pipes onto the flanges while making sure
not to hit the radiator and oil cooler. After one side of the primaries is
installed, attach one (1) spring to each of the tabs on the header pipes. Then
repeat to the other side. Make sure the radiator, as well as other hoses have
clearance from the head pipes. If using the stock O

2

sensors, reconnect the

cables. If not using stock O

2

sensors, leave the sensors disconnected.

INSTALL COLLECTOR

Install the collector to the head pipes with the two (2) supplied springs. Once the springs are on, move the collector in a
side to side and up and down motion to fully seat the collector and the header pipes.

INSTALL BRACKET

Remove the right side
passenger foot rest from
the bracket. Install the
8mm hex nut into the
opening behind the foot
peg. Attach the short end
of the bracket with the
supplied M8 x 25mm bolt
and flat washer to the foot
rest bracket. Tighten the
bolt, when tight, the bolt
and nut should not
interfere with the foot rest.
Replace the foot rest.

INSTALL MID­PIPE AND
MUFFLER

Slide the mid­pipe onto the
collector pipe
and slip the
muffler onto the

SHORT&END

DOCUMENT ID 994445

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collector pipe. Install the muffler to the bracket with the supplied bolt, washers, and locking nut, do not tighten. Install
two (2) springs at each joint and align the muffler to rest flat to the bracket and tighten the mounting bolt.
Re-check all fasteners of system to make sure everything is tightened properly.

RE-INSTALL RADIATOR / OIL COOLER BRACKET

Re-attach the radiator / oil cooler bracket, two (2) “E” clips and washers in the bottom of the radiator and oil cooler.
Insert one (1) bolt to the crankcase to fasten bracket and tighten.

CLEAN SYSTEM OF FINGER PRINTS

With any exhaust system you must clean all finger prints off before starting the motorcycle to insure there will not be
finger prints “burned” into the pipe. Carefully use alcohol, brake clean, etc. to clean the system.

INSTALL BODYWORK AND CHECK CLEARANCE

Replace all bodywork and check clearance.

Bodywork must be at lease ¼ of an inch from any part of the exhaust

system.

Brock’s Performance does not warrant burned plastic.

***CAUTION: PAIR BLOCK OFF MUST BE PERFORMED IN ORDER TO
PREVENT PREMATURE EXHAUST FAILURE. PLEASE REFER TO THE PAIR
BLOCK OFF INSTRUCTIONS THAT WERE INCLUDED OR FIND THEM AT
BROCKSPERFORMANCE.COM. FAILURE TO PERFORM THIS MODIFICATION
WILL VOID PRODUCT WARRANTY***

ADDITIONAL

Install the appropriate Power Commander map for your application: BrocksPerformance.com > Map Support

Brocks Performance Products are designed for Closed-Course Race Track use ONLY

.

Brocks Performance Products policies and warranty information: www.BrocksPerformance.com

For additional information: Check our Information Forum

at www.BrocksPerformance.com

E-mail [e-mail]

or call the Order Line 937-912-0054.