Two Brothers Racing FZ1 User Manual
V.A.L.E.
2002-05 Yamaha
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
FZ1
V.A.L.E .™ Sli p-On Exhaus t System s
Part # 0 05-290 406V / 005 -29040 7V / 005-2 90408V / 0 05-290 419V / 005- 290420 V
Parts List
Qty. Description Part Number
1 Muffler Canister Varies
1 Muffler Canister Clamp 005-2C/5C
1 Slip-on Tube 005-2904V
1 HARDWARE KIT 005-29-3
2 X-Ring (half) 005-7-2-3
1 Barrel Clamp 005-27-71MSH
1 22mm Aluminum Spacer 005-S-2210
1 10mm Flange Nut 005-FN10
1 10mm Flat Washer 005-WF10
1 10x60mm Socket Head Cap Screw 005-SH1060
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 Long Handle Ball End Hex Key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072
1 TBR Sticker Kit 015-10212
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 centerstand or ideally
a service lift during installation. Be sure to save all stock components for
possible use later.
1. Make sure the bike is completely cool before starting
the installation. Make sure the bike is secure on a
centerstand or ideally a service lift.
2. Loosen the clamp that holds the muffler connector pipe
to the headers under the bike.
3. Remove the hardware that holds the stock muffler at
TM
the passenger footpeg bracket. Take off the muffler.
Be sure you remove the gasket at the canister/header
junction. You will not reuse this gasket.
4. Assemble the V.A.L.E.™ unit. Use the 4 (four) 6x14mm
socket head cap screws and split lock washers to
loosely attach the X-Lite ™ ring to muffler inlet. Leave
loose for now.
V.A.L.E.™ Assembly Detail
5. Slide the S-bend connector pipe onto the end of the
headers, using the stainless steel T-bolt clamp to attach
it to the headers. Leave loose for now.
6. Carefully slide the muffler clamp over the muffler.
(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-bend a little to get it in the right place. Locate
both tabs of the canister clamp on the outside of the
passenger footpeg bracket. Use the supplied hardware
to secure it. Leave loose for now.
S-22-10
WF10
SH1060
Muffler Clamp
Installation Instructions
7. Make sure everything is aligned and tighten all
8. Before you run the bike, clean off all fingerprints and
Muffler Inlet
X-Lite™ Ring
S-Bend Tube
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 finish 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 fiberglass packing inside
FW10
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: For cleaning use a mild water based spray cleaner. Always apply
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.
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.
hardware. Including the V.A.L.E.™unit and barrel clamp.
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
miles, recheck all fasteners for tightness.
Care & Cleaning
005-290406V 005-290407V
V.A.L.E.
2002-05 Yamaha
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
FZ1
V.A.L.E .™ Sli p-On Exhaus t System s
Part # 0 05-290 406V / 005 -29040 7V / 005-2 90408V /
005-2 90419V / 005-2904 20V
TM
Qty. Description Part Number
1 Muffler Canister 005-206MR
1 Muffler Canister Clamp 005-2C
1 Slip-on Tube 005-2904V
1 HARDWARE KIT 005-29-3
2 X-Ring (half) 0 05-7-2-3
1 Barrel Clamp 005-27-71MSH
1 22mm Aluminum Spacer 005-S-2210
1 10mm Flange Nut 005-FN10
1 10mm Flat Washer 005-WF10
1 10x60mm Socket Head Cap Screw 005-SH1060
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 Long Handle Ball End Hex Key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072
2 TBR Script Logo Yellow Decal 4” 015-10212
005-290419V005-290408V 005-290420V
Qty. Description Part Number
1 Muffler Canister 005-207MR
1 Muffler Canister Clamp 005-2C
1 Slip-on Tube 005-2904V
1 HARDWARE KIT 005-29-3
2 X-Ring (half) 0 05-7-2-3
1 Barrel Clamp 005-27-71MSH
1 22mm Aluminum Spacer 005-S-2210
1 10mm Flange Nut 005-FN10
1 10mm Flat Washer 005-WF10
1 10x60mm Socket Head Cap Screw 005-SH1060
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 Long Handle Ball End Hex Key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072
2 TBR Script Logo Yellow Decal 4” 015-10212
Qty. Description Part Number
1 Muffler Canister 005-208MR
1 Muffler Canister Clamp 005-2C1
1 Slip-on Tube 005-2904V
1 HARDWARE KIT 005-29-3
2 X-Ring (half) 0 05-7-2-3
1 Barrel Clamp 005-27-71MSH
1 22mm Aluminum Spacer 005-S-2210
1 10mm Flange Nut 005-FN10
1 10mm Flat Washer 005-WF10
1 10x60mm Socket Head Cap Screw 005-SH1060
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 Long Handle Ball End Hex Key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072
2 TBR Script Logo Yellow Decal 4” 015-10212
Qty. Description Part Number
1 Muffler Canister 005-807MR
1 Muffler Canister Clamp 005-5C1
1 Slip-on Tube 005-2904V
1 HARDWARE KIT 005-29-3
2 X-Ring (half) 0 05-7-2-3
1 Barrel Clamp 005-27-71MSH
1 22mm Aluminum Spacer 005-S-2210
1 10mm Flange Nut 005-FN10
1 10mm Flat Washer 005-WF10
1 10x60mm Socket Head Cap Screw 005-SH1060
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 Long Handle Ball End Hex Key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072
2 TBR Script Logo Yellow Decal 4” 015-10212
Qty. Description Part Number
1 Muffler Canister 005-808MR
1 Muffler Canister Clamp 005-5C1
1 Slip-on Tube 005-2904V
1 HARDWARE KIT 005-29-3
2 X-Ring (half) 0 05-7-2-3
1 Barrel Clamp 005-27-71MSH
1 22mm Aluminum Spacer 005-S-2210
1 10mm Flange Nut 005-FN10
1 10mm Flat Washer 005-WF10
1 10x60mm Socket Head Cap Screw 005-SH1060
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 Long Handle Ball End Hex Key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072
2 TBR Script Logo Yellow Decal 4” 015-10212
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