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V.A. L.E.
2001-09 Honda
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
TRX250EX
V.A.L .E .™ Sl ip -On E xha us t S ys tem wi th M -7 A lu min um Ca ni ste r
Par t # 0 05 -20 40 406 V
Parts List
Qty. Description Part Number
1 Muffler Canister M-7 005-204-206M
1 S-Bend Tube 005-20404S
1 HARDWARE KIT 005-204-3
1 X-Lite™ V.A.L.E.™ Retaining Ring 005-7-2-2
4 6x14mm Socket Head Cap Screw 005-SH614
4 Split Lock Washer 005-WL6
1 5mm Long Handle Ball End Hex Key 005-9-18610
1 T20 Torx Bolt Hex Key 005-9-15820
1 TBR Sticker Kit 015-10212
1 Spark Arrestor (Installed) 005-106S
Installation Instructions
1. Make sure the quad is completely cool before starting
the installation. Make sure the quad is secure on a
7. Attach muffler canister to frame using the OEM bolts.
Tighten the bolt securely.
level surface and the wheels are chocked to prevent
the quad from rolling.
2. Loosen the OEM clamp connecting the slip tube to the
header.
TM
8. Securely tighten the 4 (four) 6 x 14mm hex head bolts
of the V.A.L.E. assembly.
3. Remove the two bolts securing the OEM muffler to the
frame.
9. Double check to make sure that all hardware is
securely tightened.
4. Carefully remove OEM muffler assembly from quad.
5. Use the supplied 4 (four) 6x14mm bolts and split lock
washers to loosely attach the X-Lite™ ring to muffler
inlet. (See V.A.L.E. Assembly Detail below)
Muffler Inlet
X-Lite™ Ring
10. 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.
S-Bend Tube
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. 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.
V.A.L.E.™ Assembly Detail
6. Carefully slide TBR muffler assembly onto the OEM
header making sure that the TBR slip-tube is fully
inserted.
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V.A.L.E .
2001-09 Honda
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
TRX250EX
V.A.L .E .™ Sl ip -On E xha us t S ys tem wi th M -7 A lu min um Ca ni ste r
Par t # 0 05 -20 40 406 V
Parts List
Qty. Description Part Number
1 Muffler Canister M-7 005-204-206M
1 S-Bend Tube 005-20404S
1 HARDWARE KIT 005-204-3
1 X-Lite™ V.A.L.E.™ Retaining Ring 005-7-2-2
4 6x14mm Socket Head Cap Screw 005-SH614
4 Split Lock Washer 005-WL6
1 5mm Long Handle Ball End Hex Key 005-9-18610
1 T20 Torx Bolt Hex Key 005-9-15820
1 TBR Sticker Kit 015-10212
1 Spark Arrestor (Installed) 005-106S
TM
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 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.
Care & Cleaning
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