Page 1
Installation Instructions
2006 KTM
V.A.L.E.
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
TM
250 SX-F
V.A.L .E.™ Co mp le te Ex ha us t Sy st em w it h M- 7 Ca ni ste r
Par t # 00 5- 12 9010 6V / 0 05 -1 29 107 V / 0 05 -1 29 06 07 V / 00 5- 12 90 60 8V
Parts List
Qty. Description Part Number
1 KTM250 SX-F (06) Muffler Canister M-7 Varies
1 KTM250 SX-F (06) S-Bend for Complete Varies
1 KTM250 SX-F (06) Header Varies
1 8mm Aluminum Spacer 005-S-8
1 Side Panel Spacer 005-S-13
1 6x25mm Flange Bolt 005-FB625
1 6x40mm Socket Head Cap Screw 005-SH640
1 6mm Flat Washer 005-WF6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Medium Strength Threadlock 031-P09178
4 6x14mm Socket Head Cap Screw 005-SH614
2 TBR Script Logo Yellow Decal 4” 015-10208
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. Remove seat.
3. Remove tailpiece.
4. Remove OEM upper muffler mounting bolts and springs
and disconnect muffler canister from header. Remove
muffler from bike.
5. Remove mid-pipe mounting bolt.
6. Detach header springs and save for later use.
7. Remove rear shock by removing lower and upper shock
mounting bolts.
8. With rear shock removed, remove OEM headpipe from
bike. The OEM header is a very tight fit and may be difficult
to remove.
9. Reattach rear shock.
10. Slip supplied header into frame following path of OEM
header. Attach supplied header to exhaust manifold using
OEM springs
11. Secure header to mid-pipe muffler bolt.
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.
(Continued on page 2)
Page 2
Installation Instructions
2006 KTM
V.A.L.E.
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
250 SX-F
V.A.L .E.™ Co mp le te Ex ha us t Sy st em w it h M- 7 Ca ni ste r
Par t # 00 5- 12 9010 6V / 0 05 -1 29 06 07 V / 0 05 -1 29 06 08 V
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 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 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.
12. Apply a small amount of threadlock to the four 6 x 14mm
socket head cap screws. Loosely attach the s-bend tube
to the muffler canister with the four supplied 6x14mm
socket head cap screws.
TM
13. Slip muffler assembly into header.
14. Using supplied 6x40mm bolt and 8mm spacer, attach
muffler canister to upper subframe mounting tab
15. Securely tighten the 4 (four) 6mm x 14mm hex head bolts
of the V.A.L.E. assembly.
16. Replace tailpiece using OEM left side and top bolt.
17. Using supplied 6x25mm bolt and 13mm spacer, secure
right side plastic.
18. Replace seat.
19. Double check to make sure that all hardware is tightened
20. Before you run the bike, clean off all fingerprints 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 50 to 100
miles, recheck all fasteners for tightness.
Page 3
005-1290106V
M-7 Series
3.75” x 4.85” OVAL
005-1290107V
V.A.L.E.
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
2006 KTM
250 SX-F
V.A.L .E.™ Co mp le te E xh au st S ys tem wi th M -7 C an is te r
Par t # 00 5- 12 90106 V / 00 5- 12 90107 V / 00 5- 12 90 607V / 00 5- 12 90 608V
TM
Qty. Description Part Number
1 KTM250 SX-F (06) Muffler Canister M-7 Aluminum 005-129-206M
1 KTM250 SX-F (06) Stainless Steel S-Bend for Complete 005-12901SC
1 KTM250 SX-F (06) Stainless Steel Header 005-12901H
1 8mm Aluminum Spacer 005-S-8
1 Side Panel Spacer 005-S-13
1 6x25mm Socket Head Cap Screw 005-SH625
1 6x40mm Socket Head Cap Screw 005-SH640
1 6mm Flat Washer 0 05-WF6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Medium Strength Threadlock 031-P09178
4 6x14mm Socket Head Cap Screw 005-SH614
2 TBR Script Logo Yellow Decal 4” 015-10208-A
1 Spark Arrestor (Installed) 005-106S
005-1290607V
Qty. Description Part Number
1 KTM250 SX-F (06) Muffler Canister M-7 Carbon Fiber 005-129-207M
1 KTM250 SX-F (06) Titanium S-Bend for Complete 005-12906S
1 KTM250 SX-F (06) Titanium Header 005-12906H
1 8mm Aluminum Spacer 005-S-8
1 Side Panel Spacer 005-S-13
1 6x25mm Socket Head Cap Screw 005-SH625
1 6x40mm Socket Head Cap Screw 005-SH640
1 6mm Flat Washer 005-WF6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Medium Strength Threadlock 031-P09178
4 6x14mm Socket Head Cap Screw 005-SH614
2 TBR Script Logo Yellow Decal 4” 015-10208-A
Qty. Description Part Number
1 KTM250 SX-F (06) Muffler Canister M-7 Carbon Fiber 005-129-207M
1 KTM250 SX-F (06) Stainless Steel S-Bend for Complete 005-12901S
1 KTM250 SX-F (06) Stainless Steel Header 005-12901H
1 8mm Aluminum Spacer 005-S-8
1 Side Panel Spacer 005-S-13
1 6x25mm Socket Head Cap Screw 005-SH625
1 6x40mm Socket Head Cap Screw 005-SH640
1 6mm Flat Washer 0 05-WF6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Medium Strength Threadlock 031-P09178
4 6x14mm Socket Head Cap Screw 005-SH614
2 TBR Script Logo Yellow Decal 4” 015-10208-A
005-1290608V
Qty. Description Part Number
1 KTM250 SX-F (06) Muffler Canister M-7 Titanium 005-129-208M
1 KTM250 SX-F (06) Titanium S-Bend for Complete 005-12906S
1 KTM250 SX-F (06) Titanium Header 005-12906H
1 8mm Aluminum Spacer 005-S-8
1 Side Panel Spacer 005-S-13
1 6x25mm Socket Head Cap Screw 0 05-SH625
1 6x40mm Socket Head Cap Screw 0 05-SH640
1 6mm Flat Washer 005-WF6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Medium Strength Threadlock 031-P09178
4 6x14mm Socket Head Cap Screw 0 05-SH614
2 TBR Script Logo Yellow Decal 4” 015-10208-A
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