Two Brothers Racing Harley Davidson Sportster - Manual (Page 2)

Care & Cleaning / Warranty Information
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.
Installation Instructions
Qty. Description Part Number
1 HD Sportster Muffler 005-377-M
1 HD Sportster Header 005-37701H
1 HD Sportster Heat Shield 005-377-HS1
1 HD Sportster Heat Shield 005-377-HS2
2 45mm Spring 005-S45
2 02 Sensor Plug Kit 005-92-22KIT
7 Hose Clamps 005-27-9432
2 Flange Bolt 5/16”x 3/4” 005-FB51634
2 HD Clip Nut 005-10-516CN
1 Spring Puller 005-SP
Harley Davidson
Sportster
Part # 005-3770199
10. Install O2 bungs onto TBR headers. Use copper washers and anti-
seize. Install O2 sensors onto headers. Apply anti-seize to threads.
11. Install head pipes into collector and attach springs using supplied
spring puller tool.
12. Install TBR system onto motorcycle. Leave cylinder nut slightly loose.
13. Install and tighten muffler mounting flange bolts 5/16”x 3/4”.
14. Tighten cylinder/header nuts.
15. Feed clamps through head shield retainers. Install heat shields onto
header pipes and tighten clamps.
16. Re-route O2 sensor wires and plug into main harness.
17. 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.