Two Brothers Racing BMW K1200GT - Manual

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F F u u l l l l E E x x h h a a u u s s t t S S y y y y s s t t e e m m
Parts List
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 lower fairing.
3. Unscrew the O2 sensor. Remove the stock exhaust sys-
tem at the rear canister support bracket and where it
bolts to the engine. CAUTION-the stock exhaust is very
heavy, be careful not to drop it! Also, be careful not to
damage the engine sensor located near the front header
pipe.
4. Pry out the old exhaust port gaskets and replace with
new BMW OE (x4) exhaust port gaskets. A dab of grease
will help hold the gaskets in place while you work.
5. Coat the exhaust studs and O2 sensor threads with high
temperature anti-seize compound.
6. Install the TBR headers into the exhaust ports making
sure to get a good seat onto the exhaust port gaskets.
Next, install the header nuts starting at the rear/outside
stud and working your way forward on the outside set of
studs. Once that is finished repeat along the inside set of
studs. Tighten header nuts only finger tight at this
point.
7. Be sure to coat the threads of the sensor with the includ-
ed packet of hi-temp anti-seize. Install the O2 sensor into
the TBR headers. Turning the sensor in the counter-
clockwise direction a few times then screwing it clockwise
to install will help make it easier to install and prevent the
wire from binding.
8. Place a bead of the hi-temp sealant on the outside edge
of the headers 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.
9. Carefully slide the
muffler clamp over the
muffler. (Note: The
stainless steel canis-
ter clamp and the
name badge on the
canister come from
the factory with a
clear plastic protective
film. Please remove
this film before operation.) Attach it to the canister sup-
port bracket using the stock BMW hardware. Both tabs of
the canister clamp should be located on the inside of the
canister support bracket. Leave loose for the moment.
10. Make sure everything is lined up and start to evenly tight-
en up the header nuts to BMW factory torque specifica-
tion. Tighten the canister support hardware and install the
springs as well.
11. Start the bike and check for leaks around the exhaust
ports and the header/canister junction.
12. Reinstall the lower fairing.
13. 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
Front
BMW K1200RS.qxd
Installation Instructions
Care & Cleaning / Warranty
Qty. Description Part Number
1 MUFFLER (17.5”, LEFT SIDE) VARIES
1 MUFFLER CLAMP VARIES
1 STAINLESS STEEL HEADER ASSEMBLY 005-5701N
2 80MM SPRINGS 005-S80
1 PACKET OF HI-TEMP SEALANT 031-P22072
1 PACKET OF HI-TEMP ANTI SEIZE 031-P09175
2 TBR STICKERS 015-10197
NOTE: You may also need four (4) exhaust port gaskets which are available
at your local BMW dealer. We strongly suggest replacing these gaskets
whenever installing an exhaust system to ensure a proper seal.
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.