Two Brothers Racing Harley Davidson Sportster User Manual
Installation Instructions
Harley Davidson
Sportster
Part # 005-3770199
1. Make su re the bike is c ompletel y cool befo re start ing the inst allation
and se cure on a s erv ice li ft.
2. Unplug O2 s ensor co nnector s from wir ing harnes s. Note: Pa y attent ion
to wire r outing for re inst allat ion.
3. Loose n heat s hield c lamps a nd remove heat s hields from b oth th e
front and rea r head pipes .
6. Re mo ve bo lt s t hat at ta che mufe r s to mou nti ng br ac ket . The n re mov e
bracket.
7. Re move OEM exhaus t sys tem.
8. Remove O2 sensors to in stal l on TBR head pip es.
IMPORTANT - PLEASE READ CAREFULLY
Two Brothers Racing products are intended for closed course competition
purposes only.
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 Information
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. Not tested for use with OEM or aftermarket
accessories.
4. Remove ex haus t header nuts loca ted at c ylind er head. Keep t hese
for use with TBR Comp -S sy stem.
5. Remove r ear hea d pipe c lamp bo lt. Re inst all bolt af ter cla mp is
remov ed.
9. Us in g s nap r in g pl ier s , ca ref ull y re mov e th e cir cli ps an d a n ge s fro m
th e s to c k ex ha ust sys tem . I nst all the stoc k ang es to th e new TBR he ad
pipe s. Che ck the c ondit ion of th e circ lips, w e rec ommen d repla cing
them with new o nes if t hey are b ent or t wis ted.
Installation Instructions
Harley Davidson
Sportster
Part # 005-3770199
Qty. Description Part Number
1 HD Sportster Mufer 005-377-M
1 HD Sportster Header 005-37701H
1 HD Sportster Heat Shield 005-377-HS1
1 HD Sportster Heat Shield 005-377-HS2
2 45mm Spring 005-S45
2 02 Sensor Plug Kit 005-92-22KIT
7 Hose Clamps 005-27-9432
2 Flange Bolt 5/16”x 3/4” 005-FB51634
2 HD Clip Nut 005-10-516CN
1 Spring Puller 005-SP
10. Inst all O2 bu ngs onto TBR he ader s. Use copp er wash ers an d anti-
seize. Install O2 s ensors onto h eade rs. A pply an ti-seize t o threa ds.
11. Inst all hea d pipe s into c ollec tor an d att ach sp rings using s uppli ed
sprin g pulle r tool.
12. Ins tall TBR s ystem ont o motorcyc le. Leave c ylinder nu t slightly l oose.
13. Ins tall an d tight en muf er mo untin g ange b olts 5 /16”x 3/4”.
14. Tighten cylinder/header nuts.
15. Fee d clamps thro ugh head shi eld retain ers. Inst all heat shi elds onto
header pipe s and tig hten c lamps .
16. Re- rout e O2 sens or wir es and pl ug into m ain harness .
17. Before you run the bike, clean off all ngerprints 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 rst time you start the bike. This is packing/
manufacturing oil from inside the pipe burning off. Check for gaps or
leaks. If you nd a leak, a little high temperature silicon sealant should
x it. After 50 to 100 miles, recheck all fasteners for tightness.
Care & Cleaning / Warranty Information
Care & Cleaning: Ke ep system fr ee of dirt a nd moistur e. Store in a co ol, dry p lace.
Make sure vehi cle is com pletely co ol before ma intenance .
Stainless Header System: Polished s tainles s steel pipe s will turn a li ght golde n hue
after a few he at cycles , this is a nor mal chara cterist ic of high qua lity st ainless ste el.
Clean usin g a mild water b ased spray c leaner. Alw ays apply c leaner or p olish with a
soft, c lean clot h.
Titanium Header System: Polished ti tanium pipes w ill experienc e color shift r anging from
deep blue /purple throug h amber after a few heat c ycles. This is a nor mal chara cteristic
of high qua lity tit anium. Cle an using a mil d water base d spray cle aner. Alway s apply
cleaner o r polish wi th a soft, c lean clot h.
Polished Aluminum Canisters: Use an aluminum o r mag wheel p olish to res tore the
bright finish to factory spec.
Brushed Aluminum Canisters: Clean using a m ild water based spr ay cleaner. Always
apply cl eaner or po lish with a s oft, cle an cloth.
Carbon Fiber Canisters: Clean using a mild wate r based spr ay cleane r.
Always a pply cle aner or pol ish with a sof t, clea n cloth. Al ways make sure
the fiber glass pa cking insi de is in goo d conditi on and not bur ned out, a s
exhaust he at inside an e mpty can ister will de teriorate t he carbo n fiber sle eve.
TBR sell s repack ki ts (Road - # 00 5-100 38, O ffroa d - #00 5-100 38 MX) th at includ e
every thing you ne ed to easily d o it yourse lf.
Titanium Mufflers: For cleanin g use a mild wate r based spr ay cleane r. Always app ly
cleaner o r polish with a sof t, clean cloth . Always make sure th e fiberglass p acking inside
is in good c onditio n and not bur ned out, as ex haust hea t inside an em pty cani ster will
deterior ate the car bon fibe r sleeve.
TBR sell s repack ki ts (Road - # 00 5-100 38, O ffroa d - #00 5-100 38 MX) th at includ e
every thing you ne ed to easily d o it yourse lf.
Repack a ll road can isters ever y 3,000 miles . Part # 005 -10038
Repack a ll offroa d canister s after ever y 10 hours of use. Part # 005-100 38M X
NEVER dyno test yo ur bike with carb on fiber or titani um canisters inst alled - the intense
heat and la ck of cooling air c an quickly burn th rough the caniste r material. Two Brother s
Racing d oes not prov ide a warra nty for bur ned cani sters.
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