Page 1
Installation Instructions
1. Make sure the quad is completely cool before starting the
installation. Make sure the quad is secure on a level surface
and the wheels are chocked to prevent the quad from rolling.
2. Remove the rear bed assembly:
- Remove the seats.
- Remove 3 screws and 1 push pin per side.
V.A.L.E.
2011 Polaris
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
RangeR RZR 800
V.A.L .E .™ Tri pl e Fu ll E xh au st S ys tem w it h M- 7 A lu mi nu m Ca ni st er
Par t # 00 5- 301010 6T V
IMPORTANT - PLEASE READ CAREFULLY
TM
- Remove the screws (4) behind the seats.
- Remove the screws (4) around the tail pipe.
- Remove the bolts (4) in the bed and 2 tiedown hooks.
- Unplug lights from wire harness (1) under drivers side
of bed.
- Carefully lift bed assembly off.
3. Remove OEM muffler and mid-pipe (you may need to
temporarily remove heat sheild and bed rest):
- Loosen OEM clamp.
- Remove header joint springs.
- Remove mid-pipe tension springs.
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. Be sure
to save all stock components for possible use later.
**This product has not been tested with all available accessories and some
items may cause excessive heat. Excessive heat may cause damage to your
vehicle. Two Brothers Racing will not be responsible for damaged parts.
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.
- Remove mid-pipe.
- Remove muffler assembly.
Page 2
Installation Instructions
V.A.L.E.
2011 Polaris
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
RangeR RZR 800
V.A.L .E .™ Tri pl e Fu ll E xh au st S ys tem w it h M- 7 A lu mi nu m Ca ni st er
Par t # 00 5- 301010 6T V
Installation Instructions
4. Remove OEM header assembly.
5. Remove OEM heatshield from header, reinstall on TBR header using
supplied 6x12mm cap screws and washers.
7. Remove rear frame bolts/nuts to install muffler stabilizer
mount on top of frame rail and center muffler with
mounting bracket attached under frame rail. The stock
hardware is re-used.
TM
8. Install TBR header to cylinder head using the supplied
header gasket (if the stock gasket is un-damanged
you may use that instead) and OEM mounting bolts at
header flange.
9. Locate slip-fit joint exhaust pipes and attach with
supplied springs right side slip tube marked “R” to triple
collector marked “R” and the same with “L” to “L” and
“C” to “C”. The left side exhaust pipe uses OEM tension
stop(remove from OEM exhaust and install on TBR.
6. Attach the hanger bracket to the TBR center muffler using the 4 (four)
6x14mm socket head cap screws and split lock washers provided.
10. Mount supplied muffler mounting brackets to bed
support using the supplied 8x35mm socket head cap
screws and lock washers provided, leave loose for now.
Page 3
V.A.L.E.
2011 Polaris
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
RangeR RZR 800
V.A.L .E .™ Tri pl e Fu ll E xh au st S ys tem w it h M- 7 A lu mi nu m Ca ni st er
Par t # 00 5- 301010 6T V
005-3010106TV
Installation Instructions
11. Attach muffler to muffler bracket using the supplied
8x45mm socket head cap screws with lock nuts, leave
loose for now.
14. Tighten X-ring bolts. Tighten muffler mounting bolts on
all 3 mufflers.
Qty. Description Part Number
1 Muffler Canister Left 005-279-206ML
1 Muffler Canister Center 005-275-206MC
1 Muffler Canister Right 005-279-206MR
1 Header Kit 005-30101HK
1 HARDWARE KIT 005-301-3C
6 X-Ring (half) 005-7-2-3
16 6x20mm Socket Head Cap Screw 005-SH620
16 M6 Split Lock Washer 005-WL6
4 80mm Hook Spring 005-S80
1 Header Gasket 005-275G
2 RZR Billet Muffler Mounting Bracket 005-275-21B
2 RZR Billet Muffler Mounting Lower Bracket 005-275-21BU
1 RZR Center Muffler Support Bracket 005-275B2
1 RZR Hanging Support Bracket 005-275B
2 8x1.25mm Flange Nut 005-FNL8
4 M8 Lock Washers 005-WL8
3 6x12mm Socket Head Cap Screw 005-SH612
3 6mm Flat Washer OD 18mm 005-WF6-18
4 8x35mm Socket Head Cap Screw 005-SH835
2 8x45mm Socket Head Cap Screw 006-SH845
1 Permatex Thread Lock 031-P09179
1 5mm Long Handle Ball end hex key 005-9-18610
1 T20 Torx Screw Wrench 005-9-15820
1 TBR Sticker Kit 015-10212
3 USFS Approved Spark Arrestor (installed) 005-106S
3 P1X Powertip (installed) 005-P1X
12. Attach TBR muffler to their exhaust pipes using the
supplied 6x20mm socket head cap screws and lock
washers with thread locker using the supplied 2pc.
16. Tighten muffler mounting bracket bolts, and billet
muffler mounting bracket.
X-Ring, leave loose for now.
17. Re-install seats.
15. Re-install bed assembly.
13. Make any adjustments to exhaust pipes if needed by
rotation of triple collector. Install supplied tension
springs on left and right side exhaust pipes. Left side
uses OEM spring and right uses supplied spring.
18. Double check to make sure that all hardware is securely
tightened and re-check hardware after every 10 hours.
19. Before you run the quad, 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 quad and enjoy. It is normal for some white smoke to
appear the first time you start the quad. 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
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 - #005-10 038, 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 - #005-10 038, Offroad - #005-10038MX) that include everything you need to easily do it yourself.
Repack all road canisters at the first signs of packing material deterioration. 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.
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