Page 1
Installation Instructions
TM
2004-05 Honda
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
TRX450R
V.A.L .E .™ C om pl et e Ex ha us t Sy ste m wi th M -7 C an is te r
Par t # 00 5- 106 0106 V / 00 5- 106 06 07 V / 0 05 -10 60 60 8V
Parts List
Qty. Description Part Number
1 TRX450 (04-05) Muffler Canister M-7 Varies
1 TRX450 (04-05) S-Bend for Complete Varies
1 TRX450 (04-05) Header Varies
1 22mm Aluminum Spacer 005-S-22A
1 8x85mm Socket Head Cap Screw 005-SH885
1 8mm Flange Nut 005-FN8
1 #172 Main Jet 005-105-MJ172
1 5mm Long Handle Ball end hex key 005-9-18610
4 6mm Split Lock Washer 005-WL6
4 6x14mm Socket Head Cap Screw 005-SH614
2 TBR Script Logo Yellow Decal 4” 015-10208-A
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.
1. Make sure the ATV is completely cool before starting
the installation. Make sure the bike is secure and is not
moving during installation.
2. Remove the stock exhaust system. Save hardware (except
rear muffler mounting bolt) for later use.
3. Join the V.A.L.E. cap with the end of the M-7 Canister
using the supplied 6x14mm screws. Be sure to use the
included split lock washers on all 4 of the screws. Loosely
tighten all four screws. Keep the screws loose enough so
that the tube can rotate back and forth inside the V.A.L.E.
cap.
4. Install Two Brothers titanium headpipe to ATV using stock
hardware. Snug all fasteners only finger tight for now.
5. Install entire assembly onto header gently turning it into
position so that the muffler bracket and the slip on tube
bracket line up with the appropriate holes. Now slide the
18mm aluminum spacer behind the canister mounting tab
and install the 8x85mm screw and Stock nut and tighten
finger tight.
6. Securely tighten the two 6mm x 14mm cap screws which
are accessible. This will keep the muffler and s-bend tube
aligned when the assembly is removed.
7. Carefully remove muffler assembly and s-bend from the
ATV and fully tighten all four 6mm x 14mm cap screws in an
“X” pattern. This will insure a good seal and perfect fit.
8. Re-install muffler assembly. Securely tighten all mounting
hardware.
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.
Page 2
Installation Instructions
V.A.L.E.
2004-05 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
TRX450R
V.A.L .E .™ C om pl et e Ex ha us t Sy ste m wi th M -7 C an is te r
Par t # 00 5- 106 0106 V / 00 5- 106 06 07 V / 0 05 -10 60 60 8V
9. Securely tighten header flange bolts.
10. Install the new #172 main jet in the carburetor. Refer to your
owner’s/service manual for installation procedure. Move the
needle clip to the #5 position. Remove airbox lid.
#1
#7
Needle
11. Before you run the atv, 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 atv 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. After 30-60 minutes of use, recheck all
fasteners for tightness.
TM
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.
Page 3
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
TM
2004-05 Honda
TRX450R
V.A.L .E .™ C om pl et e Ex ha us t Sy ste m wi th M -7 C an is te r
Par t # 00 5- 106 0106 V / 00 5- 106 06 07 V / 0 05 -10 60 60 8V
005-1060607V005-1060106V 005-1060608V
Qty. Description Part Number
1 TRX450 (04-05) Muffler Canister M-7 Aluminum 005-106-206M
1 TRX450 (04-05) Stainless Steel S-Bend for Complete 0 05-10601S
1 TRX450 (04-05) Stainless Steel Header 005-10601H
1 22mm Aluminum Spacer 005-S-22A
1 8x85mm Socket Head Cap Screw 005-SH885
1 8mm Flange Nut 005-FN8
1 #172 Main Jet 005-105-MJ172
1 5mm Long Handle Ball end hex key 005-9-18610
4 6mm Split Lock Washer 005-WL6
4 6x14mm Socket Head Cap Screw 005-SH614
2 TBR Script Logo Yellow Decal 4” 015-10208-A
1 Spark Arrestor (Installed) 005-106S
Qty. Description Part Number
1 TRX450 (04-05) Muffler Canister M-7 Carbon Fiber 005-106-207M
1 TRX450 (04-05) Titanium S-Bend for Complete 005-10606S
1 TRX450 (04-05) Titanium Header 005-10606H
1 22mm Aluminum Spacer 005-S-22A
1 8x85mm Socket Head Cap Screw 005-SH885
1 8mm Flange Nut 005-FN8
1 #172 Main Jet 005-105-MJ172
1 5mm Long Handle Ball end hex key 005-9-18610
4 6mm Split Lock Washer 005-WL6
4 6x14mm Socket Head Cap Screw 005-SH614
2 TBR Script Logo Yellow Decal 4” 015-10208-A
Qty. Description Part Number
1 TRX450 (04-05) Muffler Canister M-7 Titanium 005-106-208M
1 TRX450 (04-05) Titanium S-Bend for Complete 005-10606S
1 TRX450 (04-05) Titanium Header 0 05-10606H
1 22mm Aluminum Spacer 005-S-22A
1 8x85mm Socket Head Cap Screw 005-SH885
1 8mm Flange Nut 005-FN8
1 #172 Main Jet 005-105-MJ172
1 5mm Long Handle Ball end hex key 005-9-18610
4 6mm Split Lock Washer 005-WL6
4 6x14mm Socket Head Cap Screw 005-SH614
2 TBR Script Logo Yellow Decal 4” 015-10208-A
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