Two Brothers Racing Kawasaki KLX450R User Manual

V.a.l.e, Klx450r, 2008 kawasaki

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Parts List

Installation Instructions

Qty.

Description

Part Number

1

Muffler Canister

005-186-206M/207M

1

S-bend Tube with V.A.L.E. Assembly

005-18601S

1

HARDWARE KIT

005-186-3

1

Aluminum Spacer

005-S-11

1

8 x 35mm Flange Bolt

005-FB835

4

6 x 14mm Socket Head Cap Screws

005-SH614

4

6mm Split Lock Washer

005-WL6

1

5mm Long Handle Ball End Hex Key

005-9-18610

2

Two Brothers Racing Decals

015-10208-A

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

Tighten the muffler/head-pipe joint clamp.

Re-install the right side panel.

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.

9.

10.

11.

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.

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 vehicle and

exhaust system are completely cool before starting the installation. Also,

make sure the vehicle is secure on a centerstand or ideally a service lift during

installation. Be sure to save all stock components for possible use later.

Make sure the bike is completely cool before starting
the installation. Make sure the bike is secure on the
sidestand or ideally a rear service stand.

Remove right side panel.

Lossen head-pipe/muffler joint clamp.

Remove muffler mounting bolts.

Remove muffler assembly and head-pipe/muffler joint
gasket. This Gasket is not used with the TBR slip-on
system.

Attach the TBR slip-on tube to the muffler loosely with
the 4 (four) 6x14mm socket head cap screws and split
lock washers provided.

Attach the muffler assembly to the rear frame mounting
hole and slide the slip-on tube into the head-pipe. Use
the supplied 8x30mm flange bolt and spacer.

Tighten the 4 6x14mm socket head cap screws.

1.

2.

3.

4.

5.

6.

7.

8.

2008 Kawasaki

KLX450R

V.A.L.E.™ Slip-on Exhaust System with M-7 Canister
Part # 005-1860406V / 005-1860407V

Muffler Inlet

X-Lite™ Ring

Slip Tube

V.A.L.E.™ Assembly Detail

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