Two Brothers Racing KX250F User Manual

Installation Instructions

2009 Kawasaki

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

KX250F

Full Exhau st Syste m with M-7 C anister Part # 0 05-235 0106V / 005 -2350107V

Parts List

Qty. Description Part Number

1 KX250F Mufﬂer Canister M-7 Aluminum Varies 1 KX250F Header 005-23501H 1 KX250F Stainless Steel S-Bend Slip-On 005-23504S 1 HARDWARE KIT 005-235-3 2 X-Ring (half) 005-7-2-3 1 8x30mm Flange bolt 005-FB830 1 5mm Long Handle Ball end hex key 005-9-18610 4 Split Lock Washer 005-WL6 4 6x14mm Socket Head Cap Screw 005-SH614 1 TBR Sticker Kit 015-10212 1 Spark Arrestor (Installed) 005-106S

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.

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.

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 mufﬂer mounting bolt.

4. Remove lower mufﬂer mounting bolt & mufﬂer clamp.

5. Remove OEM mufﬂer assembly.

6. Remove OEM header assembly.

7. Assemble the V.A.L.E.™ unit. Use the 4 (four) 6 x 14mm socket head cap screws and split lock washers to loosely attach half X-Lite™ ring to mufﬂer inlet. Attach slip tube to mufﬂer and attach the other half loosely.

8. Install TBR header.

9. Slip S-bend tube of V.A.L.E.™ mufﬂer assembly into head pipe. Use the supplied 8x30mm Flange bolt for mufﬂer mount and OEM bolt for midpipe bracket. Leave loose for now.

10.Making sure that the V.A.L.E. ™ assembly is oriented correctly, securely tighten lower mufﬂer mounting bolt.

11. Securely tighten the 4 (four) 6 x 14mm hex head bolts of the V.A.L.E. assembly. (See V.A.L.E.™ Assembly Detail)

Mufﬂer Inlet

X-Lite™ Ring

Slip Tube

V.A.L.E.™ Assembly Detail

12.Securely tighten the upper mufﬂer mounting bolt.

13.Double check to make sure that all hardware is securely tightened and re-install side panel.

14.Re-install the side panel.

15.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.

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.

2009 Kawasaki

KX250F

Full Exhau st Syste m with M-7 C anister Part # 0 05-235 0106V / 005 -2350107V

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

005-2350106V

Qty. Description Part Number

1 KX250F Mufﬂer Canister M-7 Aluminum 005-236-206M 1 KX250F Header 050-23501H 1 KX250F Stainless Steel S-Bend Slip-On 005-23504S 1 HARDWARE KIT 005-235-3 2 X-Ring (half) 005-7-2-3 1 8x30mm Flange Bolt 005-FB830 1 5mm Long Handle Ball end hex key 005-9-18610 4 Split Lock Washer 005-WL6 4 6x14mm Socket Head Cap Screw 005-SH614 1 TBR Sticker Kit 015-10212 1 Spark Arrestor (Installed) 005-106S

005-2350107V

Qty. Description Part Number

Two Brothers Racing KX250F User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual