Two Brothers Racing Kawasaki ZZR 600 - Manual

Parts List
IMPORTANT - PLEASE READ CAREFULLY
We recommend that this performance part be installed by a qualified
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 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 a centerstand or ideally
a service lift during installation. Be sure to save all stock components for
possible use later.
Installation Instructions
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.
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. You will reuse the stock flange gasket.
If your bike has a pipe extending past the stock exhaust
flange, you’ll need to cut it off with a sharp hacksaw.
Be sure to measure twice and cut once! Typically you
can leave 1/2” of pipe extending past the flange face.
Place a bead of hi-temp sealant on the gasket
seating area on the inside of the new canister then
place the Kawasaki OE gasket into the hi-temp
sealant. 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 (8 x 16mm) through the flange holes
and into the inlet. Go ahead and tighten evenly and
fully. Wipe off any excess sealant that squeezes out.
Install the ZZR slip-on bracket to the passenger
footpeg bracket using the stock hardware.
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.) Locate both tabs of
the canister clamp on the outside of the ZZR
bracket. Use the 8 x 20mm bolt and nut to secure it.
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.
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2006-07 Kawasaki
ZZR600
Flange-on Exhaust System
Part # 005-830406M, 005-830407M, 005-830408M, 005-830419M, 005-830420M
Qty. Description Part Number
1 ZZR600 M-2 or M-5 Muffler Canister Varies
1 ZZR600 M-2 or M-5 Muffler Clamp Varies
1 8x20mm Socket Head Cap Screw 005-SH820
3 8x16mm Socket Head Cap Screw 005-SH816
1 Slip-on Bracket 005-71B
5 8mm Flat Washer 005-WF8
1 8mm Flange Nut 005-FN8
1 Permatex Ultra Black Gasket Maker 031-P22072
2 TBR Script Logo Yellow Decal 4” 015-10208-A
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: 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.
Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft,
clean cloth.
Titanium Header System: Polished titanium pipes will experience color shift ranging
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: Use an aluminum or mag wheel polish to restore the
bright finish to factory spec.
Brushed Aluminum Canisters: Clean using a mild water based spray cleaner. Always
apply cleaner or polish with a soft, clean cloth.
Carbon Fiber Canisters: Clean using a mild water based spray cleaner. Always apply
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 - #005-10038, Offroad - #005-10038MX) that include
everything you need to easily do it yourself.
Titanium Mufflers: For cleaning use a mild water based spray cleaner. Always apply
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 - #005-10038, 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.