Two Brothers Racing YZF600 User Manual

Installation Instructions

V.A.L.E.

1997-2008 Yamaha

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

YZF600

V.A.L .E .™ S li p- On E xh au st S ys te m
Par t # 0 05 -3 20 40 6V / 0 05 -3 20 40 7V / 0 05-3 20 40 8V / 0 05 -3 20 41 9V / 0 05 -3 20 42 0V

Parts List

Qty. Description Part Number

1 YZF600 Muffler Canister Varies
1 YZF600 Muffler Canister Clamp Varies
1 YZF600 Slip-On Tube 005-3204SV
1 HARWARE KIT 005-32-3
1 X-Lite™ V.A.L.E.™ Retaining Ring 005-7-2-2
1 Barrel Clamp 005-27-61MSH
1 26mm Aluminum Spacer 005-S-26
1 8x50mm Socket Head Cap Screw 005-SH850
1 8mm Nylon Lock Nut 005-NN8
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072

IMPORTANT - PLEASE READ CAREFULLY

We recommend that this performance part be installed by a qualied

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 these produ cts or part s.

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. Loosen the clamp that holds the muffler connector pipe
to the headers under the bike. Remove the hardware that
holds the stock muffler at the passenger footpeg bracket.

TM

Take off the muffler.

3.

Use the 4 (four) 6x14mm Socket Head Cap Screws and
6mm split lock washers to loosely join the slip-tube to the
muffler canister. Do night tighten yet.

4. Slide the s-bend onto the end of the headers. Secure the
support tab to the lower frame mount. Leave loose for
now.

5. Carefully slide the canister clamp over the muffler. You
may need to twist and turn the s-bend tube a little to get
it in the right place. Using the aluminum spacer, place
it between the clamp and the footpeg bracket. Locate
both tabs of the canister clamp outside of the passenger
footpeg bracket. Use the stock hardware to secure it.
Leave loose for now.

6. Once the muffler is properly aligned, tighten the muffler
mounting bolt, followed by the V.A.L.E.™ screws, and
lastly the bottom barrel clamp. Tighten the V.A.L.E.™
screws in an X-pattern in order to achieve a proper fit.

7. Before you run the bike, clean off all fingerprints and
dirt, as any oily residue will etch the metal and become
permanent when the system gets hot. Also, remove any
plastic film from the name badge(s). 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.

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:

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 - #005-10038MX) that include
everything you need to easily do it yourself.

Titanium Mufflers:

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 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

005-320408V005-320407V005-320406V

Qty. Description Part Number

1 YZF600 (89-06) M2 Aluminum Muffler Canister 005-206M
1 YZF600 (89-06) Muffler Canister Clamp 005-2C
1 YZF600 (89-06) Slip-On Tube 005-3204SV
1 HARDWARE KIT 005-32-3
1 X-Lite™ V.A.L.E.™ Retaining Ring 005-7-2-2
1 Barrel Clamp 005-27-61MSH
1 26mm Aluminum Spacer 005-S-26
1 8x50mm Socket Head Cap Screw 005-SH850
1 8mm Nylon Lock Nut 005-NN8
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072

005-320419V 005-320420V

Qty. Description Part Number

1 YZF600 (89-06) M5 Carbon Fiber Muffler Canister 005-807M
1 YZF600 (89-06) Muffler Canister Clamp 005-5C
1 YZF600 (89-06) Slip-On Tube 005-3204SV
1 HARDWARE KIT 005-32-3
1 X-Lite™ V.A.L.E.™ Retaining Ring 005-7-2-2
1 Barrel Clamp 005-27-61MSH
1 26mm Aluminum Spacer 005-S-26
1 8x50mm Socket Head Cap Screw 005-SH850
1 8mm Nylon Lock Nut 005-NN8
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072

Qty. Description Part Number

1 YZF600 (89-06) M2 Carbon Fiber Muffler Canister 005-207M
1 YZF600 (89-06) Muffler Canister Clamp 005-2C1
1 YZF600 (89-06) Slip-On Tube 005-3204SV
1 HARDWARE KIT 005-32-3
1 X-Lite™ V.A.L.E.™ Retaining Ring 005-7-2-2
1 Barrel Clamp 005-27-61MSH
1 26mm Aluminum Spacer 005-S-26
1 8x50mm Socket Head Cap Screw 005-SH850
1 8mm Nylon Lock Nut 005-NN8
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072

Qty. Description Part Number

1 YZF600 (89-06) M5 Titanium Muffler Canister 005-808M
1 YZF600 (89-06) Muffler Canister Clamp 005-5C1
1 YZF600 (89-06) Slip-On Tube 005-3204SV
1 HARDWARE KIT 005-32-3
1 X-Lite™ V.A.L.E.™ Retaining Ring 005-7-2-2
1 Barrel Clamp 005-27-61MSH
1 26mm Aluminum Spacer 005-S-26
1 8x50mm Socket Head Cap Screw 005-SH850
1 8mm Nylon Lock Nut 005-NN8
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072

Qty. Description Part Number

1 YZF600 (89-06) M2 Titanium Muffler Canister 005-208M
1 YZF600 (89-06) Muffler Canister Clamp 005-2C2
1 YZF600 (89-06) Slip-On Tube 005-3204SV
1 HARDWARE KIT 005-32-3
1 X-Lite™ V.A.L.E.™ Retaining Ring 005-7-2-2
1 Barrel Clamp 005-27-61MSH
1 26mm Aluminum Spacer 005-S-26
1 8x50mm Socket Head Cap Screw 005-SH850
1 8mm Nylon Lock Nut 005-NN8
4 6x14mm Socket Head Cap Screws 005-SH614
4 6mm Split Lock Washer 005-WL6
1 5mm Long Handle Ball end hex key 005-9-18610
1 Permatex Ultra Black Gasket Maker 031-P22072