Two Brothers Racing Honda 919 - Manual

Mfg: Honda Make: 919
Year: All
Product: Full Exhaust System
1- Header Assembly
1- Canister (slip-on, right exit)
1- Canister clamp
1- S-bend
4- Connector springs (#005-S80)
1- 6mm x 40mm bolt
1- 6mm washer
1- 10mm x 16mm hex bolt
1- 8mm x 20mm bolt
1- 8mm washer 1- 8mm nut
1- Hanger bracket
1- Packet of Hi-Temp Anti-Seize
1- Packet of Hi-Temp Sealant
1- Rear Stainless Steel Brake Line
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 pre-
vent 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 fiber-
glass packing inside is in good condition and not burned out, as exhaust heat inside an empty canister will deterio-
rate 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.
Warranty
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 deal-
er. Read all instructions first before starting installation.
Make sure the motorcycle and exhaust system are com-
pletely 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 side-
stand or ideally a rear service stand.
2. Remove the grab rail, seat and tail section.
3. Remove the 6mm x 10mm buttonhead bolts from the
underside of the rear fender.
4. Loosen the clamps that hold the stock canisters at the
“Y” connector pipe. Remove the stock mufflers.
5. You will need raise and support the rear of the motorcy-
cle and remove the rear shock in order to remove the “Y”
connector pipe. The rear shock must be removed in order
to remove the “Y” connector pipe from the motorcycle.
6. After removing the “Y” connector pipe reinstall the rear
shock. Be sure to torque all bolts to factory specifications.
7. Replace the stock rear brake line with the stainless steel
line provided. Be sure the brake line does not touch
the exhaust system.
8. Unbolt and remove the headers from the bike.
CALIFORNIA BIKES ONLY-On California (CA) bikes the
emissions canister is in the way and will need to be
removed in order to mount the TBR headers. You will
need to disconnect hose “A” from the exhaust solenoid
and plug it using the 10mm x 16mm hex bolt. You can
then remove hose “B” (the other end of this hose con-
nects to the right side of the emissions canister). Unhook
hose “C” (smaller diameter hose) from the emissions
canister and let it vent to the atmosphere. Unbolt the
emission canister bracket and remove the assembly from
the bike.
9. Carefully pry out the old exhaust port gaskets and
replace them with new exhaust port gaskets. A small dab
of grease will hold them in place while you mount the
new header.
10. Apply anti-seize to the exhaust studs. Install the new
headers, do not tighten yet.
11. Place a bead of the hi-temp sealant on the outside edge
of the headers. Install the S-bend onto the header. Wipe
off the excess sealant that will squeeze out.
12. Attach the hanger bracket to the right side passenger
footpeg bracket (see photos).
13. Place a bead of the hi-temp sealant on the outside edge
of the s-bend that goes into the canister. Slide the TBR
canister onto the end of the S-bend pipe. Wipe off the
excess sealant that will squeeze out.
14. Carefully slide the muffler clamp over the muffler. (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.)
You may need to twist and turn the S-bend a little to get it
in the right place. Locate both tabs of the canister clamp
outside of the hanger bracket. Use the 8mm bolt, washer
and nut to secure it. Leave loose for now.
15. Make sure everything is aligned and tighten all hardware
starting at the front of the bike first. Affix the connector
springs.
16. Reinstall the grab rail and tail section. Be sure to check
the operation of the key prior to reinstalling the seat as
the lock mechanism can easily be jammed during seat
cowl installation. DO NOT INSTALL SEAT IF KEY CAN-
NOT BE REMOVED FROM LOCK MECHANISM.
Reinstall seat only after lock works properly.
17. Before you run the bike, clean off all fingerprints and dirt,
as any oily residue will etch the metal and become some-
what 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/manufac-
turing 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
See reverse for installation photos
919 Full System Instructions.qxd
Installation Instructions
Care & Cleaning / Warranty
NOTE: You may also need four (4)
exhaust port gaskets which are avail-
able at your local Honda dealer. We
strongly suggest replacing these gas-
kets whenever installing a full exhaust
system to ensure a proper seal.