Two Brothers Racing FZ09 User Manual
Installation Instructions
Yamaha
FZ-09
Full Exhaust System
Part # 005-3790105-S1
Parts List
Qty. Description Part Number
1 Mufer 10” Carbon S1
1 Mufer Clamp 005-2C-S1H
1 Header Assembly 005-37901H
1 Bracket 005-379-B
2 8x30mm Flange Bolt 005-FB830
2 45mm Swivel Hook Spring 005-S45
1 8x16mm Socket Head Cap Screw 005-SH816
3 8mm Flange Nut 005-FN8
1 Permatex Anti-seize Lubricant 031-P09175
2 Zip Ties 005-ZT458B
1 Air Block Off Plug 005-PLUG-1
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 vehicle and
exhaust system are completely cool before starting the installation. Also, make
sure the vehicle 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.
1. Make s ure the bike is completely cool before starting
the ins talla tion. Make sure the bike is secure on the side
stand or ideally a rear service s tand.
2. Remove O2 sensor from OEM header pipe.
3. Loosen head pipe hardware .
4. Remove mufer mounting bolts.
5. Remove OEM exhaust assembly.
6. Attach the TBR header assembly using OEM hard ware
and gaskets . Leave loose for now.
7. Attach supplied mufer mounting bracket using t wo
8x3 0mm bolts and two 8mm ange nuts.
8. Slide S1R muf er c lamp over S1R mufer assembly.
Note: Direc tion of mufer clamp for install.
9. Slide mufer onto header assembly and attach with
provided springs. Note: Apply a small amount of anti-
seize b etween mufer and head pipe.
Yamaha
FZ-09
Full Exhaust System
Part # 005-3790105-S1
Installation Instructions
10. Attach mufer clamp to bracket using supplied 8x16mm
socket head bolt and 8mm ange nut. Leave lo ose for
now.
11. Apply small amount of anti-seize to O2 sensor threads
and install O2 s ensor into head pipe.
12. Tighten all hardware st arting with header, mufer clamp,
and bracket .
Parts List
Qty. Description Part Number
1 Mufer 10” Carbon S1
1 Mufer Clamp 005-2C-S1H
1 Header Assembly 005-37901H
1 Bracket 005-379-B
2 8x30mm Flange Bolt 005-FB830
2 45mm Swivel Hook Spring 005-S45
1 8x16mm Socket Head Cap Screw 005-SH816
3 8mm Flange Nut 005-FN8
1 Permatex Anti-seize Lubricant 031-P09175
2 Zip Ties 005-ZT458B
1 Air Block Off Plug 005-PLUG-1
13. Before you run the bike, clean off all ngerprint s and
dirt , as any oily residue will etch the metal and be come
somew hat permanent when the sys tem ge ts hot. Run
the bike and enjoy. It is normal for some white s moke to
appear the rst time you start the bike. This is packing/
manufacturing oil from inside the pipe burning of f.
Check for gaps or leaks. If you nd a leak , a lit tle high
temperature silic on sealant should x it. After 50 to 100
miles, recheck all fasteners for tightness.
14. Note: Due to the fact that the catalytic converter is no
longer present, the PAIR (Pulsed Air Induc tion Re ed)
valve is not needed and will not e ffect performance
when eliminated. It is recommended that the PAIR
valve be modied to eliminate popping or backring
on deceleration. Plugging the air line is a simple and
eff ective procedure. This is accessible from the left side
of the motorcycle. Start by cut ting the pictured air hose
and install the provided plug in line. Zip tie both sides of
hose over the plug.
Care & Cleaning
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.
Brushed Aluminum Canisters: Clean using a mild water based spray cleaner. Always
apply cleaner or polish with a soft, clean cloth.
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, Off road - #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, Off road - #005-10038MX) that include
everything you need to easily do it yourself.
Repack all road canisters every 3,000 miles. Part #005-10038
Repack all Off road canisters after every 10 hours of use. Part #005-10038MX
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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