Two Brothers Racing Suzuki SV1000 - Manual

Parts List
IMPORTANT - PLEASE READ CAREFULLY
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
motorcycle and exhaust system are completely cool before starting the
installation. Also, make sure the bike is secure on a centerstand or ideally
a service lift during installation. Be sure to save all stock components for
possible use later.
Installation Instructions
1. Make sure the bike is completely cool before
starting the installation. Make sure the bike is
secure on a centerstand or ideally a service lift.
2. Remove the stock canisters at the passenger footpeg
bracket and where they bolt to the end of the exhaust
pipe. You will reuse the stock exhaust gaskets.
3. Install the new canisters, with the stock exhaust
gaskets, onto the stock pipe flange using the 8mm x
20mm bolts and 8mm washers. Leave loose for now.
4. Carefully slide the canister clamps over the canisters. (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 clamps on the outside of
the passenger footpegs. Secure using the stock hardware.
5. Make sure everything is aligned and tighten all.
6. 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.
Qty. Description Part Number
1 Flange-on Muffler Canister (Right Side) Varies
1 Flange-on Muffler Canister (Left Side) Varies
2 Muffler Canister Clamp Varies
1 HARDWARE KIT 005-102-3
8 8mm Flat Washer 005-WF8
8 8x20mm Socket Head Cap Screw 005-SH820
1 Sticker Kit 015-10212
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.
2003-07 Suzuki
SV1000/1000S
Flange-On Exhaust System with DUAL Exhaust Canisters
Part # 005-1020406M / 005-1020407M / 005-1020408M / 005-1020419M / 005-1020420M