Two Brothers Racing Kawasaki ZRX1200 - Manual

Kawasaki ZRX1200
Flange-On Exhaust System
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 flange cover at the front of the canister by
unscrewing bolts that are found inside holes in the cover.
You will be re-using this cover.
3. Remove the nuts holding the stock canister onto the
flange. Loosen the hardware that holds the canister to
the passenger footpeg and remove the canister from the
bike.
4. If your bike has the pipe extending past the flange you
will need to trim it. This will not affect refitting the stock
canister if you ever need to. Be sure to measure twice
and cut once! Typically you can leave 1/2” of pipe
extending past the flange face.
5. Install the canister onto the end of the stock exhaust
flange (the TBR badge faces to the outside). You’ll have
to hold it in place while you start the 8mm x 20mm bolts
through the flange holes and into the inlet. Go ahead and
tighten evenly and fully.
6. Install the hanger bracket to the passenger footpeg
bracket using the stock hardware. The bracket should
point backward and down toward the canister. Leave
loose for now.
7. Carefully slide the canister clamp over the canister.
(Note: The stainless steel canister clamp and the name
badge on the canister come from the factory with a clear
plastic protective film. Please remove this film before
operation.) Locate both tabs of the canister clamp on the
outside of the hanger bracket. Use the 8mm x 20mm
bolt, washers and nut to secure it. Leave loose for now.
8. Make sure everything is aligned and tighten all hardware.
Reinstall the flange cover.
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
Canister Clamp Detail
ZRX1200 Flange-On Instructions.qxd
Installation Instructions
Canister Clamp Detail
1/2”
QTY. DESCRIPTION PART NUMBER
1 C4 MUFFLER (17.5”, RIGHT SIDE, FLANGE # E115) VARIES
1 C4 MUFFLER CLAMP VARIES
1 HARDWARE KIT 005-74-3
4 8X20MM SOCKET HEAD CAP SCREWS 005-SH820
6 8MM FLAT WASHER 005-WF8
1 8MM NYLON LOCK NUT 005-NN8
1 MUFFLER BRACKET 005-17B
2 TWO BROTHERS RACING DECALS 015-10208-A
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.
Care & Cleaning / Warranty