Two Brothers Racing Zuma 125 User Manual

Make sure the bike is completely cool before starting
1. the installation. Make sure the bike is secure on a centerstand or ideally a service lift.
Remove OEM O2 sensor from head pipe.
2.
Mount muffler support bracket and fender support
6. using the supplied 8mm flange bolt and nut provided.
V.A.L.E.
2009
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
Yamaha Zuma 125
V. A.L.E. ™ Full Exhaus t System with M-2 Ca nister Part # 0 05-247 0106V / 005 -2470107V / 005-2 470108V
Parts List
Qty. Description Part Number
1 Muffler Canister M-2 Varies 1 Header 005-24701H 1 Muffler Clamp Varies 1 HARDWARE KIT 005-247-3 2 X-Ring (half) 005-7-2-3 1 Scooter SS Bolt-on Support Bracket 005-187B 1 Long Muffler Mounting Bracket 005-247-B 1 Fender Support Bracket 005-247-BS 2 8mm Flange Nut 005-FN8 1 6x20mm Socket Head Cap Screw 005-SH620 1 M6 Flat Washer (18mm OD) 005-WF6-18 1 10x25mm Black Flange Bolt 005-FB1025B 3 8x16mm Flange Bolt 005-FB816 4 6x14mm Socket Head Cap Screw 005-SH614 4 6mm Split Lock Washer 005-WL6 1 5mm Long Handle Ball End Hex Key 005-9-18610 1 T20 Torx Short Hex Key 005-9-15820 1 TBR Sticker Kit 015-10212
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.
TM
Remove OEM headpipe by removing the 3 mounting
3. bolts and header nuts keeping rubber grommet in rear fender for re-use.
Install TBR muffler to TBR header pipe using the
7. 6x14mm socket head cap screws and lock washers provided, leave loose for now.
Install TBR header pipe assembly and mount muffler
Install TBR long muffler mounting bracket using the
4. supplied 10mm flange bolt in the front and 8mm flange bolt in the back.
Mount the fender support with the 6x20mm socket
5. head cap screw and washer through rubber grommet into fender support bracket.
8. using the rubber lines supplied muffler clamp and secure with the supplied flange bolt and nut.
When muffler is aligned correctly tighten the header
9. flange nuts and muffler mounting X-Ring bolts.
Re-install the OEM O2 sensor.
10.
Before you run the bike, clean off all fingerprints and
11. 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.
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
2009
Yamaha Zuma 125
V. A.L.E. ™ Full Exhaus t System with M-2 Ca nister Part # 0 05-247 0106V / 005 -2470107V / 005-2 470108V
Care & Cleaning / Warranty
Care & C leaning
Keep sys tem fr ee of d irt and moistu re. St ore in a cool , dry place. For cl eaning use a m ild sp ray cle aner. Always apply cleaner or po lish wi th a s oft, cle an clot h.
Stainle ss Hea der Syste m:
hue afte r a fe w heat cycles , this is a no rmal char acteri stic of high quality stainle ss ste el.
Carbon Fiber Mufflers :
good co nditio n and n ot bur ned out , as e xhaust heat i nside a n empt y canis ter will de terior ate the Carbo n Fiber sleev e. T BR sell s repa ck kits ( TBR part # 00 5-
10038) that in clude new ri vets a nd repa ck materi al as w ell as a dril l bit (#30), making it eas y to do your self. Also , NEVER dyno t est yo ur bik e with carbon fiber mu fflers instal led - the int ense h eat and lack of coolin g air c an quickl y cause t he CF materia l to b urn. Two Brothe rs Raci ng doe s not p rovide a warrant y for bur ned ca rbon fib er.
Aluminum Mufflers:
restore the b right fi nish t o facto ry spe c.
Warranty Info rmation
Two B rother s Rac ing pr oducts are intend ed fo r clos ed co urse c ompet ition purpos es on ly, and there fore a re so ld “as is” withou t war ranty. Two Bro thers Racin g spec ifica lly di s clai ms an y warr antie s of m ercha ntabil ity o r fitn ess f or a p articu lar p urpose and discla ims all respo nsibil ity f or con seque ntial and i nciden tal d amages or an y oth er los ses a rising from the use of thes e prod ucts or par ts.
Polished stainl ess st eel pip es wil l turn a ligh t golde n
Always ma ke sur e the fibergla ss packin g insi de is i n
Use an aluminum or mag wheel polish such as Mother’s to
005-2470107V005-2470106V 005-2470108V
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Qty. Description Part Number
1 Muffler Canister M-2 005-187-206M 1 Header 005-24701H 1 Muffler Clamp 005-2C 1 HARDWARE KIT 005-247-3 2 X-Ring (half) 005-7-2-3 1 Scooter SS Bolt-on Support Bracket 005-187B 1 Long Muffler Mounting Bracket 005-247-B 1 Fender Support Bracket 005-247-BS 2 8mm Flange Nut 005-FN8 1 6x20mm Socket Head Cap Screw 005-SH620 1 M6 Flat Washer (18mm OD) 005-WF6-18 1 10x25mm Black Flange Bolt 005-FB1025B 3 8x16mm Flange Bolt 005-FB816 4 6x14mm Socket Head Cap Screw 005-SH614 4 6mm Split Lock Washer 005-WL6 1 5mm Long Handle Ball End Hex Key 005-9-18610 1 T20 Torx Short Hex Key 005-9-15820 1 TBR Sticker Kit 015-10212
Qty. Description Part Number
1 Muffler Canister M-2 005-187-207M 1 Header 005-24701H 1 Muffler Clamp 005-2C1 1 HARDWARE KIT 005-247-3 2 X-Ring (half) 005-7-2-3 1 Scooter SS Bolt-on Support Bracket 005-187B 1 Long Muffler Mounting Bracket 005-247-B 1 Fender Support Bracket 005-247-BS 2 8mm Flange Nut 005-FN8 1 6x20mm Socket Head Cap Screw 005-SH620 1 M6 Flat Washer (18mm OD) 005-WF6-18 1 10x25mm Black Flange Bolt 005-FB1025B 3 8x16mm Flange Bolt 005-FB816 4 6x14mm Socket Head Cap Screw 005-SH614 4 6mm Split Lock Washer 005-WL6 1 5mm Long Handle Ball End Hex Key 005-9-18610 1 T20 Torx Short Hex Key 005-9-15820 1 TBR Sticker Kit 015-10212
Qty. Description Part Number
1 Muffler Canister M-2 005-187-208M 1 Header 005-24701H 1 Muffler Clamp 005-2C2 1 HARDWARE KIT 005-247-3 2 X-Ring (half) 005-7-2-3 1 Scooter SS Bolt-on Support Bracket 005-187B 1 Long Muffler Mounting Bracket 005-247-B 1 Fender Support Bracket 005-247-BS 2 8mm Flange Nut 005-FN8 1 6x20mm Socket Head Cap Screw 005-SH620 1 M6 Flat Washer (18mm OD) 005-WF6-18 1 10x25mm Black Flange Bolt 005-FB1025B 3 8x16mm Flange Bolt 005-FB816 4 6x14mm Socket Head Cap Screw 005-SH614 4 6mm Split Lock Washer 005-WL6 1 5mm Long Handle Ball End Hex Key 005-9-18610 1 T20 Torx Short Hex Key 005-9-15820 1 TBR Sticker Kit 015-10212