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8. Remove lo wer lef t and right fairing s.
9. Remove fr ont hea der cove r.
10. Remove he ader pip es.
11. Using the O EM copp er gask et bet ween header col lar and
cylind er head. I nsta ll TBR he ader usi ng OEM bol ts.
12. Remo ve lower re ar set mo unting b olt and r eplac e with
suppli ed 8x4 0mm soc ket hea d cap sc rew.
Installation Instructions
1. Make su re the bik e is compl etel y cool be fore s tart ing
the inst allation. Make su re the bike i s secu re on a cen ter
stand o r ideall y a serv ice lif t.
2. Remove si de cover s and se at.
3. Remove re ar pass enger s eat.
4. Remove OEM r ear fen der. You will reu se the fe nder bo lts.
5. Remove re ar exhau st cove r.
6. Remove exh aust va lve cabl es fro m servo u nder se at. Us e
a wrenc h to hold s erver w heel in p lace or in ternal g ears
may break.
7. R emove OEM m ufe r asse mbly.
Kawasaki
ZX-636
Full Exhaust System
Part # 005-3860105-S1
*Keep servo plugged
into harness but cables
will not be used.
IMPORTANT - PLEASE READ CAREFULLY
We recommend that this performance part be installed by a qualied 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 rst 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.
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 nish 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 berglass packing inside is in good condition and not burned out, as exhaust
heat inside an empty canister will deteriorate the carbon ber sleeve.
TBR sells repack kits (Road - #005-10038, Offroad - #005-10038MX) that include everything you need to easily do
it yourself.
Titanium Mufers: For cleaning use a mild water based spray cleaner. Always apply cleaner or polish with a soft,
clean cloth. Always make sure the berglass packing inside is in good condition and not burned out, as exhaust
heat inside an empty canister will deteriorate the carbon ber 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 rst signs of packing material deterioration. Part #005-10038
NEVER dyno test your bike with carbon ber 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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13. Att ach the s upplie d mounti ng brac ket to the i nside of
frame an d secur e in plac e with th e suppli ed 8mm an ge
nut. Br acket s hould be i nstal led as sh own in pic ture.
14. Appl y a thin laye r of anti- seize to slip tube o utlet a nd
atta ch TBR m ufe r using su pplied h ook spr ings. In stal l
barrel c lamp ont o slip tub e.
15. Inst all rubb er lined m ufe r clamp ove r canis ter. Moun t
the slip -tube u sing the s upplie d 10mm nut a nd OEM
bolt.
16. Atta ch the T BR muf er ass embly u sing the ange bol t
and nut to s ecure t he muf er in pla ce.
17. Check a lignmen t and tigh ten muf er.
Installation Instructions
Qty. Description Part Number
1 S1R Canister Varies
1 Mufer Clamp Varies
1 Header 005-24101H
1 Slip Tube 005-38601S
1 Barrel Clamp 005-27-63MSH
1 Mufer Bracket 005-241-B
1 Fender Bracket 005-19904B
2 Lighted License Plate Bolt 005-8504LT2
1 Turn Signals (set of 2) 005-88T2
6 Butt Splice Connectors 005-BS1614
1 Zip Tie 005-ZT458B
1 Zip Tie Tab 005-ZTM4
1 8x40mm Socket Head Cap Screw 005-SH840
4 6mm Flange Nut 005-FN6
1 8x16mm Flange Bolt 005-FB816
2 8mm Flange Nut 005-FN8
1 10mm Nut 005-NN11
2 45mm Spring 005-S45
1 Spring Puller 005-SP
Left Turn Signal
(Grey connector)
Red
Plate Lights
Right Turn Signal
(Black connector)
Wiring Harness
Red
Black
Kawasaki
ZX-636
Full Exhaust System
Part # 005-3860105-S1
18. Tighten barrel clamp.
19. Insta ll TBR fe nder eli minator k it usin g the orig inal bol ts
and supp lied nut s, the nuts will be i nside th e bike und er
seat.
20. Attac h turn sig nals and p late ligh t bolt s using th e wire
splice c onnectors su pplied t o the cor rect w ires in t he
harnes s as show n in the Wir ing Diag ram.
21. Re- insta ll seat s and cove rs.
22. Double ch eck all yo ur work.
23. Before you r un the bik e, clean o ff all n gerpr ints an d
dirt, a s any oily r esidu e will etc h the met al and be come
somewh at per manent w hen the s ystem g ets ho t. Also,
remove an y plast ic lm fro m the name b adge(s) an d or
canis ter clam p(s). Run the b ike and enj oy. It is norm al for
some whi te smoke t o appea r the rs t time you s tar t the
bike. Thi s is pac king/ manufa cturi ng oil fro m inside t he
pipe bur ning of f. Chec k for gaps o r leaks . If you nd a
leak, a li ttle h igh temp eratu re silic on seala nt shoul d x it.
Afte r 50 to 100 mil es, re chec k all fas tener s for tigh tness .
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