Two Brothers Racing Suzuki Bandit 600 - Manual

Congratulations on your purchase of a Two Brothers Racing
exhaust system. 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, please
consult with your local motorcycle dealer.
Parts List
1- Muffler Canister (right side slip-on)
1- Muffler clamp
2- Muffler joint springs
1- S-bend tube
1- Black “Y” bracket
1- 8mm x 55mm allen bolt
1- 8mm x 50mm allen bolt
1- 8mm x 25mm allen bolt
3- 8mm Flange Nuts
5- 8mm washer
NOTE-You will need to reuse the stock exhaust gasket.
Installation Instructions
Please read these instructions completely before starting and
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 original muffler being careful not to damage the
exhaust gasket. If you damage the gasket you can get a new
one from your local Suzuki dealer. In most cases you can
reuse the original gasket.
3. Install the black “Y” bracket as shown by removing the rear
allen bolt from the passenger footrest and replacing it with the
supplied 8mm x 55mm allen bolt. Securely tighten the 8mm x
55mm allen bolt. Next, attach the “Y” bracket to the extra
thread using the nylock nut and washer only finger tight. Now
attach the bottom half of the Y bracket using the supplied
8mm x 50mm allen bolt, nylock nut and washer. Now securely
tighten the entire assembly.
4. Remove the rubber center stand bumper from your original
pipe and install it in the TBR s-bend tube.
5. Slide the TBR s-bend into the header just like the original but
do not tighten the clamp yet.
6. Slide the muffler onto the s-tube and attach the muffler to the
“Y” bracket with the muffler clamp using the supplied 8mm x
25mm allen bolt, nylock nut and washers. NOTE: Both ears of
the clamp must squeeze together and mount on the outside of
the “Y” bracket.
7. Carefully rotate the connector tube and muffler slightly if need-
ed to align everything. Once satisfied you can now install the
springs and tighten all the fasteners. Start at the front of the
bike and work your way backwards.
8. 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.
9. Run the bike and enjoy. It is normal for some white smoke to
appear the first time you start the bike. This is packing/manu-
facturing 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 fasten-
ers for tightness.
Installation Instructions
Slip-on Exhaust for
SUZUKI Bandit 600
Bandit600.qxd
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.
Care and 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.
Chrome Header System: Chromed header tubing will turn blue close to
the exhaust ports, this is normal. To prevent corrosion you must keep
the header pipes clean.
Carbon Fiber & X-Metal Mufflers: 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 (part # 005-10038) that include new rivets and the right
size drill bit, making it easy to do yourself. Also, NEVER dyno test your
bike with carbon fiber mufflers 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 Disclaimer
Two Brothers Racing products are intended for closed course competi-
tion 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 con-
sequential and incidental damages or any other losses arising from the
use of these products or parts.
8mm x 55mm
rear allen bolt
8mm x 50mm
bottom allen bolt
Relocated Centerstand Bumper
“Y” Bracket
8mm x 25mm