Two Brothers Racing Aprilia Falco User Manual

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Parts List

We recommend that this performance exhaust system
be installed by a qualified motorcycle technician. If you
have any doubts as to your ability to install this exhaust
system, 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 the sidestand or ideally a rear
service stand during installation. Be sure to save all
stock exhaust components for possible use later.

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. Unhook the springs that hold the stock canisters to the
headers.

3. Remove the bolts that attach the stock canisters to the
footpegs.

4. Take off the stock canisters.

5. Place a bead of hi-temp sealant on the outside edge of
the headers that goes into the TBR s-bends. Slide the S­bends onto the end of the headers. Leave loose for

now.

6. Place a bead of the hi-temp sealant on the outside edge
of the s-bend that goes into the canisters. Slide the TBR
canisters onto the end of the S-bend pipes. Wipe off the
excess sealant that will squeeze out.

7. Carefully slide the canister
clamps over the canisters.
(Note: The stainless steel

canister clamp and the
name badge on the canis­ter come from the factory
with a clear plastic protec­tive film. Please remove
this film before operation.)

You may need to twist and
turn the S-bends a little to get it in the right place. Using
the aluminum spacer, place it between the clamp and the
footpeg bracket. Attach it to the footpeg bracket using the
longer bolt provided and stock nut. Leave loose for

now.

8. Make sure everything is aligned and tighten all hardware.
Affix the connector springs to the muffler.

9. 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/manufac-

turing 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.

IMPORTANT - PLEASE READ CAREFULLY

Aprilia Falco Slip-On Instructions.qxd

OE Exhaust System

Installation Instructions

Care & Cleaning / Warranty

QTY. DESCRIPTION PART NUMBER

1 MUFFLER (17.5”, RIGHT SIDE) VARIES
1 MUFFLER (17.5”, LEFT SIDE) VARIES
2 MUFFLER CLAMP VARIES
1 S-BEND TUBE -

LEFT SIDE 005-1804NL

RIGHT SIDE 005-1804NR
4 80MM SPRINGS 005-S80
2 18MM SPACER 005-S-18
2 8MM X 60MM SOCKET HEAD CAP SCREW N/A
2 8MM WASHERS N/A
1 HI-TEMP SEALANT 031-P22072
2 TWO BROTHERS RACING STICKERS 015-10197

Front

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.
Chrome Header System: Chromed header tubing will turn blue close to the
exhaust ports, this is normal. To prevent corrosion you must keep the header
pipes clean.
Carbon Fiber & X-Metal Mufflers: X-Metal CF canisters will shift color from their
original silver color to an amber color after a few heat cycles, similar to the way
our stainless steel headers shift color. 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 / X-Metal CF 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.

W

arranty

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.