Two Brothers Racing TL1000S User Manual

Mfg: Suzuki Make: TL1000S

TL1000S Flange-On Instructions.qxd

Year: All
Product: Flange-On Exhaust System

IMPORTANT - PLEASE READ CAREFULLY

We recommend that this performance exhaust system
be installed by a qualified motorcycle technician. If you
have any doubts as to your ability to install this exhaust
system, please consult with your local motorcycle deal­er. Read all instructions first before starting installation.
Make sure the motorcycle and exhaust system are com ­pletely cool before starting the installation. Also, make
sure the bike is secure on the sidestand or ideally a rear
service stand during installation. Be sure to save all
stock exhaust components for possible use later.

Installation Instructions

1. Make sure the bike is completely cool before starting the
installation. Make sure the bike is secure on the side­stand or ideally a rear service stand.

2. Remove the stock canisters at the passenger footpeg
brackets and where they bolt to the end of the exhaust
pipe. You will reuse the stock exhaust gaskets.

Parts List

2- Canisters (flange-on, right &left

exit)
2- Canister Clamps
8- 8mm x 25mm Bolts
8- 8mm Washers
1- 8mm Spacer

(For use with C2 canisters only)

Care & Cleaning / Warranty

Care & Cleaning

Keep system free of dirt and moisture. Store in a cool, dry place. For cleaning use a mild spray cleaner. Always
apply cleaner or polish with a soft, clean cloth.
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.
Chrome Header System: Chromed header tubing will turn blue close to the exhaust ports, this is normal. To pre­vent corrosion you must keep the header pipes clean.
Carbon Fiber & X-Metal Mufflers: X-Metal CF canisters will shift color from their original silver color to an amber
color after a few heat cycles, similar to the way our stainless steel headers shift color. 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 / X-Metal CF sleeve. TBR sells repack kits (TBR part # 005-10038) that include new rivets
and repack material as well as a drill bit (#30), making it easy to do yourself. Also, NEVER dyno test your bike with
carbon fiber mufflers installed - the intense heat and lack of cooling air can quickly cause the CF material to burn.
Two Brothers Racing does not provide a warranty for burned carbon fiber.
Aluminum Mufflers: Use an aluminum or mag wheel polish such as Mother’s to restore the bright finish to factory
spec.

Warranty

Two Brothers Racing products are intended for closed course competition purposes only, and therefore are sold “as
is” without warranty. Two Brothers Racing specifically disclaims any warranties of merchantability or fitness for a
particular purpose and disclaims all responsibility for consequential and incidental damages or any other losses
arising from the use of these products or parts.

3. Install the new canisters onto the stock pipe flange using
the 8mm x 25mm bolts and 8mm washers. Leave loose

for now.

4. Carefully slide the canister clamps over the canisters.
(Note: The stainless steel canister clamp and the name

badge on the canister come from the factory with a clear
plastic protective film. Please remove this film before
operation.) Locate both tabs of the canister clamps on

the outside of the passenger footpegs. Secure using the
stock hardware. Use the 8mm x 20mm bolt, nut and
washer to secure it. Leave loose for now.

NOTE: for C2 canisters, install the 8mm spacer on
the right side only- see diagram.

5. Make sure everything is aligned and tighten all hardware.
Start at the flanges then the canister clamps.

6. 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.

OE Exhaust System

Canister Clamp Detail

Right Side

C4/C5 Canisters ONLY

Right Side

C2 Canisters ONLY