Two Brothers Racing Kawasaki KLR650 User Manual

Klr650, Kawasaki

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Parts List

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.

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

1.

Make sure the bike is completely cool before starting the
installation. Make sure the bike is secure on a centerstand
or ideally a service lift.

2.

Remove right side panel.

3.

Remove upper muffler mounting bolts.

4.

Loosen muffler joint clamp.

5.

Remove muffler assembly.

6.

Attach S1R muffler to TBR slip tube using supplied hook
springs. Loosely install barrel clamp onto slip tube inlet.

7.

Install muffler clamp onto muffler.

Qty.

Description

Part Number

1

S1 Muffler Canister

Varies

1

Muffler Clamp

005-2C-S1

1

S1 Slip-On Tube

005-40104S

1

Barrel Clamp

005-27-58MSH

2

Spring

005-S45

1

8x75mm Socket Head Cap Screw

005-SH875

1

Spacer

005-S-34

1

8mm Flat Washer

005-WF8

1

8mm Flange Nut

005-FN8

1

Spring Puller

005-SP

1

Permatex Anti-Seize

031-P09175

Kawasaki

KLR650

Slip-On Exhaust System
Part # 005-4010406-S1

8.

Install muffler and slip tube into mounting position.

9.

Install S1R mounting hardware bolt, washer, clamp,
spacer, and nut. Securely tighten.

10. Securely tighten the lower muffler barrel clamp.

11. Re-install right side panel.

Double check to make sure that all hardware is fully
tightened.

12. 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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