Two Brothers Racing BMW R1100S - Manual

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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 seat, rear side panels and number plate.
3. Remove the stock canister assembly. Do not remove
the header pipes or catalytic converter.
4. Install the slip-on connector onto the stock collector
reusing the BMW clamp. Leave loose for now.
5. Install the canister hanger bracket onto the two horizontal
posts that supported the stock mufflers (ref. illustration). It
may be necessary to lightly tap the bracket into place
with a hammer. Make sure the hanger bracket is fully
engaged onto the posts and that there is at least 1/4” of
post extending past the new hanger bracket. Drill one
2.5mm hole through each post and install the supplied
stainless steel hitch pin clips. These clips will prevent the
mufflers from sliding back on the hanger posts.
6. Place a bead of the hi-temp sealant on the outside edge
of the slip-on connector that go into the canisters. Slide
the canisters onto the end of the s-bend connector. Wipe
off the excess sealant that will squeeze out. Rotate the
canisters to the proper orientation and install the springs.
7. Assemble the canister clamps and hardware (ref. illustra-
tion). Leave loose for now.
8. Install the slip-on connector/canister assembly onto the
collector. Attach the slip-on connector/canister assembly
to the hanger bracket using the 8mm x 50mm bolt.
Carefully align all pipes, canisters and hardware. When
everything is in place, tighten all hardware and clamps.
Don’t forget to tighten the front head pipe nuts, crossover
pipe clamp and O
2 sensor. Connector the license plate
lights to the wiring harness.
9. 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
License Plate Hanger Detail
BMW R1100S Slip-On C2 and C4 Instructions.qxd
Installation Instructions
Care & Cleaning / Warranty
OE Exhaust Detail
C4 Canisters NOTE: Muffler view
may differ depending
on the type of canister
you ordered.
Muffler Hanger Bracket 32mm x 15mm Spacer
License Plate Hanger
Lighted Bolts
(*note orientation
of light coverage
and wire routing
behind license
plate hanger)
Muffler Clamp
View from rear of bike
QTY. DESCRIPTION PART NUMBER
1 C4 ROUND MUFFLER (10”, LEFT SIDE) VARIES
1 C4 ROUND MUFFLER (10”, RIGHT SIDE) VARIES
2 MUFFLER CLAMPS VARIES
1 SLIP-ON “Y” CONNECTOR 005-8504N
1 MUFFLER HANGER BRACET 005-8504M
1 32MM X 15MM SPACER 005-S-32
1 LICENSE PLATE HOLDER 005-8504L
1 LITZ N’ BOLTS 005-8504LT
1 8MM X 50MM SOCKET HEAD CAP SCREW N/A
2 HITCH PINS N/A
4 75MM SPRINGS 005-S75
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.
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.