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
TM
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 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.
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.
TM
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
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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