Two Brothers Racing Suzuki Z400 Quadsport - Manual

2009 Suzuki Z400 QuadSport
V.A.L.E.™ Slip-on Exhaust System with M-7 Canister
Part # 005-2370406v
Parts List
Installation Instructions
Qty. Description Part Number
1 Muffler Canister M-7 Aluminum 005-109-206
1 Slip-On Tube 005-23704S
1 HARDWARE KIT 005-237-3
1 V.A.L.E.™ X-lite Ring 005-7-2-2
1 8x45 Socket Flat Head Cap Screw 005-SHF845
1 8x60 Socket Flat Head Cap Screw 005-SHF860
2 8mm Aluminum Washers (Gold) 005-WA8G
1 18mm Spacer (Gold) 005-S-18SG
1 34mm Spacer (Gold) 005-S-34SG
1 5mm Long Handle Ball end hex key 005-9-18610
4 M6 Split Lock Washer 005-WL6
4 6x14mm Socket Head Cap Screw 005-SH614
V.A.L.E.
V a r i a b l e a x i s l o c k i n g e x h a u s t
TM
Before you run the ATV, 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 ATV and enjoy. It is normal for some white smoke to
appear the first time you start the ATV. 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.
8.
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.
IMPORTANT - PLEASE READ CAREFULLY
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 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 vehicle and
exhaust system are completely cool before starting the installation. Also,
make sure the vehicle is secure on a centerstand or ideally a service lift during
installation. Be sure to save all stock components for possible use later.
Make sure the ATV is completely cool before starting
the installation. Make sure the ATV is secure on a level
surface and the wheels are chocked to prevent the ATV
from rolling.
Remove the stock slip on (1 bolt at the top of the
muffler, 1 bolt at the bottom of the muffler and 1 bolt at
the header)
Assemble the V.A.L.E.™unit by slipping the S-bend
tube through the X-Lite™ ring. Use the 4 (four) 6 x
14mm socket head cap screws and split lock washers
to loosely attach the X-Lite™ ring to muffler inlet. (See
V.A.L.E.™ Assembly Detail below)
Install spacers in rubber mounts as shown.
Install entire assembly onto header gently turning it into
position so that the rubber mount holes line up with the
stock mounting holes on the frame.
Install and tighten the 8x60mm (bottom bolt) and the
8x45mm (upper bolt) and securely fasten the canister to
the frame. Be sure to use threadlock on the threads.
Tighten the 4 socket head cap screws on
V.A.L.E.™muffler joint in a cross-type pattern. Securely
tighten.
1.
2.
3.
4.
5.
6.
7.
Muffler Inlet
X-Lite™ Ring
Slip Tube
insert 34mm spacer in lower Mount insert 18mm spacer in upper Mount