Two Brothers Racing Suzuki Bandit 1200 - Manual

Mfg: Suzuki Make: Bandit 1200
Year: 1997-2000
Product: Flange-On Exhaust System
Parts List
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.
Chrome Header System: Chromed header tubing will turn blue close to the exhaust ports, this is normal. To pre-
vent corrosion you must keep the header pipes clean.
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 fiber-
glass packing inside is in good condition and not burned out, as exhaust heat inside an empty canister will deterio-
rate 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 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
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 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 nuts/bolts 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. You will reuse the stock flange gasket.
3. Install the canister with the gasket onto the end of the
stock exhaust flange (the TBR badge faces to the out-
side). You’ll have to hold it in place while you start the
nuts/bolts through the flange holes and into the inlet. Go
ahead and tighten evenly and fully.
4. Carefully slide the muffler clamp over the muffler. ( 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 passenger footpeg bracket. Use the stock hardware
to secure it.
5. 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
Bandit 1200 Flange-On Instructions.qxd
Installation Instructions
Care & Cleaning / Warranty
r e b m u N t r a P n o i t p i r c s e D . y t Q
1 Muffler Canister (flange-on, right exit) Varies
1 Canister Clamp with Rubber Liner Varies
3 - 5 7 - 5 0 0 T I K E R A W D R A H 1
0 2 8 H S - 5 0 0 t l o B d a e H t e k c o S m m 0 2 x 8 3
8 F W - 5 0 0 s r e h s a W m m 8 3
1
Permatex Ultra Black Gasket Maker 031-P22072
1 Sticker Kit 015-10212