Two Brothers Racing XR650 User Manual

Installation Instructions

2000-07 Honda

XR650R

Sl ip- on V. A.L .E .™ Ex haust Sy stem wi th M- 7 C an ist er Par t # 0 05 -54 04 06V

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

Parts List

Qty. Description Part Number

1 XR650R Aluminum Mufﬂer Canister M-7 005-54-206M 1 XR650R Stainless Steel S-Bend Tube 005-5401S 1 Barrel Clamp 005-27-59MSH 1 8mm Flat Washer 005-WF8 1 18mm Aluminum Spacer 005-S-18 1 20mm Aluminum Spacer 005-S-2013 1 5mm Long Handle Ball end hex key 005-9-18610 1 Permatex Medium Strength Threadlock 031-P09178 4 6x14mm Socket Head Cap Screw 005-SH614 1 8x40mm Socket Head Cap Screw 005-SH840 4 6mm Split Lock Washer 005-WL6 2 TBR Script Logo Yellow Decal 4” 015-10208-A

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. 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.

1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on a centerstand or ideally a service lift.

2. Remove right sidepanel.

3. Remove upper mufﬂer mounting bolt.

4. Remove lower mufﬂer mounting bolt.

5. Remove mufﬂer assembly.

6. Assemble the

V.A.L.E.™unit by slipping the S-bend tube through the X-Lite™ ring. Apply threadlock to the 4 (four) 6 x 14mm bolts and loosely attach the X-Lite™ ring to mufﬂer inlet.

(See V.A.L.E.

7. Slip S-bend tube of

™ Assembly Detail below)

V.A.L.E.™mufﬂer assembly into head pipe. Use supplied 8 x 40mm socket head screw to loosely attach upper and lower mufﬂer mounts. Apply threadlock to mounting bolts and loosely secure.

Mufﬂer Inlet

X-Lite™ Ring

S-Bend Tube

V.A.L.E.™ Assembly Detail

8. Making sure that the V.A.L.E.™assembly is oriented correctly, securely tighten upper mufﬂer mounting bolt with 18mm spacer.

9. Securely tighten the 4 (four) 6 x 14mm hex head bolts of the V.A.L.E.™assembly.

10. Securely tighten the lower mufﬂer mounting bolt with 20mm spacer.

11. I nsert supplied si de panel sp ac er onto s up pl ie d 6 x 25 mm f la ng e bo lt a nd reinstall side panel.

12. Double check to make sure that all hardware is tightened

13. 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

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:

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:

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:

bright ﬁnish to factory spec.

Brushed Aluminum Canisters:

apply cleaner or polish with a soft, clean cloth.

Carbon Fiber Canisters:

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 - #005-10 038MX) that include everything you need to easily do it yourself.

Titanium Mufﬂers:

Repack all road canisters every 3,000 miles. 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.

Polished stainless steel pipes will turn a light golden hue

Polished titanium pipes will experience color shift ranging

Use an aluminum or mag wheel polish to restore the

Clean using a mild water based spray cleaner. Always

Clean using a mild water based spray cleaner. Always apply

For cleaning use a mild water based spray cleaner. Always apply

V.A.L.E.

M-7 Series

3.75” x 4.85” OVAL

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

2000-07 Honda

XR650R

Sl ip- On V. A.L .E .™ Ex haust Sy stem wi th M- 7 C an ist er Par t # 0 05 -54 04 06V

005-540406V

Qty. Description Part Number

Two Brothers Racing XR650 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual