Two Brothers Racing BMW F650GS - Manual

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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 stock exhaust canisters.
3. Install the 90 o bracket on the left side of the bike per the
photo. Reuse the stock torx bolt to secure.
4. Place a bead of the hi-temp sealant on the outside edge
of the header that goes into the S-bend. Slide the barrel
clamp onto the end of the s-bend (the end with the slots
cut into it). Slide the S-bend and barrel clamp onto the
end of the header. Wipe off the excess sealant that will
squeeze out.
5. 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.
6. 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 90
o bracket. Use the 8mm x 20mm flange
bolt and 8mm nut & washer to secure it. Leave loose for
now.
7. Make sure everything is aligned and tighten all hardware.
Affix the connector springs to the muffler.
8. 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
BMW F650GS Slip-On Instructions.qxd
Installation Instructions
Care & Cleaning / Warranty
Parts List
Picture taken from underneath left side of bike
Finished Installation detail
QTY. DESCRIPTION PART NUMBER
1 C4 ROUND MUFFLER (17.5”, LEFT SIDE) VARIES
1 MUFFLER CLAMP VARIES
1 S-BEND TUBE 005-4504N
2 80MM SPRINGS 005-S80
1 8MM X 20MM FLANGE HEAD BOLTS N/A
1 8MM NYLOCK NUT N/A
1 8MM WASHER N/A
1 BARREL CLAMP (27-61MSH) 005-27-61MSH
1 90-DEGREE BRACKET (WITH 8MM HOLES) 005-44TB
1 HI-TEMP SEALANT 031-P22072
2 TWO BROTHERS RACING STICKERS 015-10197
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 muf-
flers 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 dis-
claims all responsibility for consequential and incidental damages or any other losses
arising from the use of these products or parts.