Two Brothers Racing DR-Z400E User Manual

2000-07 Suzuki

DR-Z400E

V.A.L.E.™ Sli p-on Exh aust System with M-7 Cani ster Part # 0 05-189040 6V / 005-189040 7V

V.A.L.E.

V A R I A B L E A X I S L O C K I N G E X H A U S T

Installation Instructions

Tighten the barrel clamp.

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.

Remove right side panel.

Remove mufﬂer assembly from motorcycle leaving head

pipe attached. You will need to remove the heatshield too.

Use OEM mounting hardwarend to re-install the heat shield.

Attach the TBR mid-pipe to the mufﬂer using the 4

socket head cap screws and split lock washers provided.

Re-install side panel.

Do not tighten yet.

10.

Mufﬂer Inlet

Before you run the bike, clean off all ﬁngerprints and

X-Lite™ Ring

Slip Tube

11.

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

V.A.L.E.™ Assembly Detail

miles, recheck all fasteners for tightness.

Parts List

Qty. Description Part Number

1 Mufﬂer Canister 005-189-206M/207M 1 S-bend Tube with V.A.L.E. Assembly 005-18901S 1 HARDWARE KIT 005-189-3 1 22mm Spacer 005-5-22A 1 Barrel Clamp 005-27-59MSH 1 8mm Flat Washer 005-WF8 4 6x14mm Socket Head Cap Screws 005-SH614 4 M6 Split Lock Washer 005-WL6 1 8x55mm Socket Head Cap Screw 005-SH855 1 Ball End Hex Wrench 005-9-18610 2 Two Brothers Racing Decals 015-10208-A

IMPORTANT - PLEASE READ CAREFULLY

We recommend that this performance part be installed by a qualied

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 vehicle and exhaust system are completely cool before starting the installation. Also, make sure the vehicle is secure on a centerstand or ideally a service lift during installation. Be sure to save all stock components for possible use later.

Warranty

Two Brothe rs Racing p roducts are intended fo r closed co urse compet ition purpo ses only, and therefore are sold “a s is” without warranty. Two B rothers Rac ing specifi cally discla ims any war ranties of merchantabi lity or fit ness for a particular purpose and discla ims all res ponsibility for conseq uential and incidental damages or any other losses aris ing from the use of thes e products or parts.

Slide the supplied barrel clamp onto the mid-pipe at

pipe joint and attach mufﬂer assembly to motorcycle

using the 8x16mm ﬂange bolt and 8x55mm bolt with

spacer and OEM nut.

Make sure mufﬂer is lined up straight and tighten upper

mufﬂer mount and mid-pipe mount.

Tighten the 4 6x14mm socket head cap screws joining

the mufﬂer to the mid-pipe.

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:

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:

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:

bright ﬁnish to factory spec.

Brushed Aluminum Canisters:

apply cleaner or polish with a soft, clean cloth.

Carbon Fiber Canisters:

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.

Titanium Mufﬂers:

Repack all road canisters every 3,000 miles. Part #005-10038 Repack all offroad canisters after every 10 hours of use. Part #005-10038MX

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.

Polished stainless steel pipes will turn a light golden hue

Polished titanium pipes will experience color shift ranging

Use an aluminum or mag wheel polish to restore the

Clean using a mild water based spray cleaner. Always

Clean using a mild water based spray cleaner. Always apply

For cleaning use a mild water based spray cleaner. Always apply

M-7 Series

3.75” x 4.85” OVAL

2000-07 Suzuki

DR-Z400E

V.A.L.E.™ Sli p-on Exh aust System with M-7 Cani ster Part # 0 05-189040 6V / 005-189040 7V

005-1890406V

Qty. Description Part Number

1 Mufﬂer Canister 005-189-206M 1 S-bend Tube with V.A.L.E. Assembly 005-18901S 1 HARDWARE KIT 005-189-3 1 22mm Spacer 005-5-22A 1 Barrel Clamp 005-27-59MSH 1 8mm Flat Washer 005-WF8 4 6x14mm Socket Head Cap Screws 005-SH614 4 M6 Split Lock Washer 005-WL6 1 8x55mm Socket Head Cap Screw 005-SH855 1 Ball End Hex Wrench 005-9-18610 2 Two Brothers Racing Decals 015-10208-A

005-1890406V

Qty. Description Part Number

1 Mufﬂer Canister 005-189-207M 1 S-bend Tube with V.A.L.E. Assembly 005-18901S 1 HARDWARE KIT 005-189-3 1 22mm Spacer 005-5-22A 1 Barrel Clamp 005-27-59MSH 1 8mm Flat Washer 005-WF8 4 6x14mm Socket Head Cap Screws 005-SH614 4 M6 Split Lock Washer 005-WL6 1 8x55mm Socket Head Cap Screw 005-SH855 1 Ball End Hex Wrench 005-9-18610 2 Two Brothers Racing Decals 015-10208-A

Two Brothers Racing DR-Z400E User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual