Two Brothers Racing Yamaha Zuma 125 - Manual

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
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
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.
Remove OEM O2 sensor from head pipe.
Remove OEM headpipe by removing the 3 mounting
bolts and header nuts keeping rubber grommet in rear
fender for re-use.
Install TBR long muffler mounting bracket using the
supplied 10mm flange bolt in the front and 8mm flange
bolt in the back.
Mount the fender support with the 6x20mm socket
head cap screw and washer through rubber grommet
into fender support bracket.
1.
2.
3.
4.
5.
Mount muffler support bracket and fender support
using the supplied 8mm flange bolt and nut provided.
Install TBR muffler to TBR header pipe using the
6x14mm socket head cap screws and lock washers
provided, leave loose for now.
Install TBR header pipe assembly and mount muffler
using the rubber lines supplied muffler clamp and
secure with the supplied flange bolt and nut.
When muffler is aligned correctly tighten the header
flange nuts and muffler mounting X-Ring bolts.
Re-install the OEM O2 sensor.
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.
6.
7.
8.
9.
10.
11.
Qty. Description Part Number
1 Muffler Canister M-2 Varies
1 Header 005-24701H
1 Muffler Clamp Varies
1 HARDWARE KIT 005-247-3
2 X-Ring (half) 005-7-2-3
1 Scooter SS Bolt-on Support Bracket 005-187B
1 Long Muffler Mounting Bracket 005-247-B
1 Fender Support Bracket 005-247-BS
2 8mm Flange Nut 005-FN8
1 6x20mm Socket Head Cap Screw 005-SH620
1 M6 Flat Washer (18mm OD) 005-WF6-18
1 10x25mm Black Flange Bolt 005-FB1025B
3 8x16mm Flange Bolt 005-FB816
4 6x14mm Socket Head Cap Screw 005-SH614
4 6mm Split Lock Washer 005-WL6
1 5mm Long Handle Ball End Hex Key 005-9-18610
1 T20 Torx Short Hex Key 005-9-15820
1 TBR Sticker Kit 015-10212
2009
Yamaha Zuma 125
V.A.L.E.™ Full Exhaust System with M-2 Canister
Part # 005-2470106V / 005-2470107V / 005-2470108V
Parts List