Two Brothers Racing KLR650 User Manual

Kawasaki

KLR650

Slip-On Exhaust System Part # 005-4010406-S1

Installation Instructions

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. Remove right side panel.

3. Remove upper mufer mounting bolts.

8. Install mufer and slip tube into mounting position.

9. Install S1R mounting hardware bolt, washer, clamp, spacer, and nut. Securely tighten.

Parts List

Qty. Description Part Number

1 S1 Mufer Canister Varies 1 Mufer Clamp 005-2C-S1 1 S1 Slip-On Tube 005-40104S 1 Barrel Clamp 005-27-58MSH 2 Spring 005-S45 1 8x75mm Socket Head Cap Screw 005-SH875 1 Spacer 005-S-34 1 8mm Flat Washer 005-WF8 1 8mm Flange Nut 005-FN8 1 Spring Puller 005-SP 1 Permatex Anti-Seize 031-P09175

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 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.

4. Loosen mufer joint clamp.

5. Remove mufer assembly.

6. Attach S1R mufer to TBR slip tube using supplied hook

springs. Loosely install barrel clamp onto slip tube inlet.

10. Securely tighten the lower mufer barrel clamp.

11. Re-install right side panel. Double check to make sure that all hardware is fully

tightened.

12. 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.

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.

7. Install mufer clamp onto mufer.

Kawasaki

KLR650

Slip-On Exhaust System Part # 005-4010406-S1

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, Offroad - #005-10038MX) that include everything you need to easily do it yourself.

Titanium Mufers: 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, 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 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.