Two Brothers Racing Suzuki Z400 Quadsport - Manual

2003-10 Kawasaki KFX400
2003-08 Suzuki Z400 QuadSport
V.A.L.E.™ Slip-on Exhaust System with M-7 Canister
Part # 005-1090406
Installation Instructions
V.A.L.E.
V A R I A B L E A X I S L O C K I N G E X H A U S T
TM
8. Use the supplied threadlock. Tighten the 4 socket head
cap screws on V.A.L.E.™muffler joint in a cross-type
pattern. Securely tighten.
9. Tighten the Band Clamp and check your work to be
sure all hardware is securely tightened.
10. Install the new #165 main jet in the carburetor. Refer
to your owner’s/service manual for installation
procedure. Keep the needle clip in the stock position.
Remove airbox lid.
11. Before you run the ATV, 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 ATV and enjoy. It is normal for
some white smoke to appear the first time you start
the ATV. 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.
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.
IMPORTANT - PLEASE READ CAREFULLY
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.
1. Make sure the ATV is completely cool before starting
the installation. Make sure the ATV is secure on a level
surface and the wheels are chocked to prevent the ATV
from rolling.
2. Remove the stock slip on (1 bolt at the top of the
muffler, 1 bolt at the bottom of the muffler and 1 bolt at
the header)
3. Assemble the V.A.L.E.™unit by slipping the S-bend
tube through the X-Lite™ ring. Use the 4 (four) 6 x
14mm socket head cap screws and split lock washers
to loosely attach the X-Lite™ ring to muffler inlet. (See
V.A.L.E.™ Assembly Detail below)
4. Install spacers in rubber mounts as shown.
5. Install band clamp loosely on connector tube as shown.
6. Install entire assembly onto header gently turning it into
position so that the rubber mount holes line up with the
stock mounting holes on the frame.
7. Install and tighten the 8x60mm (bottom bolt) and the
8x45mm (upper bolt) and securely fasten the canister to
the frame. Be sure to use threadlock on the threads.
Muffler Inlet
X-Lite™ Ring
Slip Tube
Insert 34mm Spacer in Lower Mount Insert 18mm Spacer in Upper Mount
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. Be sure
to save all stock components for possible use later.
**This product has not been tested with all available accessories and some
items may cause excessive heat. Excessive heat may cause damage to your
vehicle. Two Brothers Racing will not be responsible for damaged parts.