Two Brothers Racing ZR-7 User Manual

Mfg: Kawasaki Make: ZR-7
Year: 2000-01
Product: Flange-On Exhaust System

1- Canister (flange-on, right exit)
1- Canister clamp
3- 8mm x 25mm Bolts (flange)
1- TL Bracket
1- 8mm x 40mm Bolt
1- 8mm x 20mm Bolt
1- 8mm Nylock Nut
4- 8mm Washer

Parts List

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.

W

arranty

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.

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 com­pletely 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.

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 flange cover at the front of the canister by
unscrewing two allen head bolts that are found inside
holes in the cover. You will re-use this cover later.

3. Remove the nuts holding the stock canister onto the
flange. Loosen the hardware that holds the canister to
the passenger footpeg and remove the canister from the
bike.

4. You will need to trim the pipe extending past the flange.
This will not affect refitting the stock canister if you ever
need to. Be sure to measure twice and cut once!
Typically you can leave 1/2” of pipe extending past the
flange face.

5. Install the canister onto the end of the stock exhaust
flange (the TBR badge faces to the outside). You’ll have
to hold it in place while you start the bolts (8mm x 25mm)
through the flange holes and into the inlet. Go ahead and
tighten evenly and fully.

6. Install the TL bracket to the passenger footpeg bracket
using the 8mm x 40m bolt, washer and nut. The bracket
should point backward and be parallel with the canister.

Leave loose for now.

7. Carefully slide the canister clamp over the canister.
(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 clamp on the

outside of the TL bracket. Use the 8mm x 20mm bolt,
washer and nut to secure it. Leave loose for now.

8. Make sure everything is aligned and tighten all hardware.

9. Reinstall the flange cover.

10.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.

IMPORTANT - PLEASE READ CAREFULLY

Canister Clamp Detail

ZR-7 Flange-On Instructions.qxd

Flange Detail

Installation Instructions

Care & Cleaning / Warranty

1/2”

Front