Two Brothers Racing Kawasaki ZX-7R - Manual

K K a a w w a a s s a a k k i i Z Z X X - - 7 7 7 7 R R
F F l l a a n n g g e e - - O O n n E E x x h h a a u u s s t t S S y y y y s s t t e e m m
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 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 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 sidestand or
ideally a rear service stand.
2. Remove the flange cover at the front of the canister by
unscrewing two allen head bolts that are found inside holes
in the cover. You will re-use this cover later.
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. You may need to trim the pipe extending past the flange. 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 bolts (8mm x 20mm) through the
flange holes and into the inlet. Go ahead and tighten evenly
and fully.
6. Carefully slide the canister clamp over the canister. (Note:
The stainless steel canister
clamp and the name badge on
the canister come from the fac-
tory with a clear plastic protec-
tive film. Please remove this
film before operation.) Locate
both tabs of the canister clamp
on the outside of the passen-
ger footpeg bracket. Use the
stock to secure it. Leave
loose for now.
7. Make sure everything is aligned and tighten all hardware.
8. 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 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.
IMPORTANT - PLEASE READ CAREFULLY
Canister Clamp Detail
Front
ZX-7R Flange-On Instructions.qxd
OE Exhaust System
Installation Instructions
Flange Detail
1/2”
QTY. DESCRIPTION PART NUMBER
1 MUFFLER (17.5”, RIGHT SIDE) -
C2 MUFFLER (FLANGE # E029) VARIES
C4 MUFFLER (FLANGE # E091 WITH 93-95 ORIENTATION) VARIES
C5 MUFFLER (FLANGE # E128) VARIES
1 MUFFLER CLAMP VARIES
3 8MM X 20MM SOCKET HEAD CAP SCEWS N/A
3 8MM WASHERS N/A
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.
Care & Cleaning / Warranty