Two Brothers Racing KLX140 User Manual
Kawasaki
KLX-140
Comple te Exhau st System with M 6 Canis ter
Part # 0 05-2090106M
Parts List
Qty. Description Part Number
1 M6 AL Muffler Canister 005-209-204M
1 Header Pipe 005-20901H
1 Spark Arrestor (installed) 005-107-S
1 Spark Arrestor Spacer (installed) 005-107-S1
1 HARDWARE KIT 005-209-3
1 Permatex Ultra Black Gasket Maker 031-P22072
2 Two Brothers Racing Decals 015-10208-A
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.
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.
Make sure the bike is completely cool before
1.
starting the installation. Make sure the bike is
secure on the sidestand.
Remove the right, rear number plate panel.
2.
Remove the stock exhaust system.
3.
Install the TBR header.
4.
Place a bead of the hi-temp sealant on the outside
5.
edge of the header that goes into the canister.
Slide the TBR canister onto the end of the header.
Wipe off the excess sealant that will squeeze out.
Use the OEM bolt to secure muffler assembly to
6.
subframe.
Make sure everything is properly aligned and
7.
tighten all hardware.
Before you run the bike, clean off all fingerprints
8.
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 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 your first ride, recheck all
fasteners for tightness.
Installation Instructions
Qty. Description Part Number
1 M6 AL Muffler Canister 005-209-204M
1 Header Pipe 005-20901H
1 Spark Arrestor (installed) 005-107-S
1 Spark Arrestor Spacer (installed) 005-107-S1
1 HARDWARE KIT 005-209-3
1 Permatex Ultra Black Gasket Maker 031-P22072
2 Two Brothers Racing Decals 015-10208-A
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 - #005-10 038, Offroad - #005-10038MX) that include
everything you need to easily do it yourself.
Titanium Mufflers:
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 - #005-10 038, 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.
005-2090106M
Care & Cleaning
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
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