Two Brothers Racing RZR900 User Manual

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 seats.

4. Remove exhaust pipe joint springs(2) above rear right wheel.

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 900 XP

V.A.L .E .™ D ua l 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- 30 9010 6DV

5. Remove 6 header ﬂange bolts and remove OEM header system.

3. Tilt the panel forward behind the seats to access the header pipes.

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. 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.

6. Remove mufﬂer retaining springs(2) and remove OEM mufﬂer assembly.

Page 2

Installation Instructions

9. Re-route the clear hose from behind the driver seat to go under the frame bar.

2011 Polaris

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

RangeR RZR 900 XP

V.A.L .E .™ D ua l 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- 30 9010 6DV

Installation Instructions

7. Remove OEM bolts above left and right wheel wells as shown in photo.

8. Install new supplied mounting bracket in both wheel wells using supplied 8x25mm bolts and rear bolts will use supplied 8mm nuts.

11. Install header collars and ﬂanges with spring hook ears on top as shown.

10. Using supplied 6x14mm bolt and nut install rubber liner to retaining bracket and mount as shown behind drivers seat. Loosely wrap hoses and bracket with supplied ziptie, make sure you have rubber side down on bracket.

12. Install headers using supplied spring hooks as shown, tighter radius header installs on passanger side.

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 900 XP

V.A.L .E .™ D ua l 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- 30 9010 6DV

005-3090106DV

Qty. Description Part Number

1 Mufﬂer Canister Left 005-309-206ML 1 Mufﬂer Canister Right 005-309-206MR 1 Header Kit 005-30901H 1 HARDWARE KIT 005-309-3C 1 Mufﬂer Mounting Bracket - Left 005-309-BL 1 Mufﬂer Mounting Bracket - Right 005-309-BR 1 Retaining Bracket 005-309-B 1 High Temp Rubber Liner 005-LC 2 Header Collar 005-309-15S 2 Header Flanges 005-309-17 2 X-Ring (half) 005-7-2-2 8 6x20mm Socket Head Cap Screw 005-SH620 8 M6 Split Lock Washer 005-WL6 4 80mm Spring 005-S80 6 8x1.25mm Locking Flange Nut 005-FNL8 1 6x14mm Socket Head Cap Screw 005-SH614 1 6mm Flange Nut 005-FN6 8 8x25mm Socket Head Cap Screw 005-SH825 1 Zip tie 005-ZTB 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 2 USFS Approved Spark Arrestor (installed) 005-106S

Installation Instructions

13. Loosely attach slip tubes to TBR exhaust canisters

15. Tighten X-ring bolts. using the supplied 6x20mm bolts, washers and X-rings as shown. The shorter tube goes on canister on the passenger side.

16. Replace panel and seats.

17. Double check to make sure that all hardware is securely

tightened and re-check hardware after every 10 hours.

18. 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/

14. Install TBR mufﬂer assemblys to header tubes on both sides and secure in place with supplied 8x25mm bolts with lock nuts to mounting bracket.

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 - #005-10 038, 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.