Two Brother Racing DR650 1998-05 Suzuki Instruction Manual

Two Brother Racing DR650 1998-05 Suzuki

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 center stand or ideally a service lift during installation. Be sure to save all stock components for possible use later.

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.

Installation Instructions

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 right side number plate.
3. Remove plate to access joint clamp.
4. Loosen joint clamp.
5. Remove three OEM mounting bolts. One bolt will be used with TBR system. Remove OEM muffler assembly.
6. Attach slip-tube using provided hook springs.
7. Slide TBR slip-tube into OEM header. OEM gasket will be used with TBR system. Tighten joint clamp.
8.  Install OEM bolt to mount TBR slip tube. Re-install OEM cover plate and tighten mounting bolts.
9. Slide muffler clamp over S1R muffler and attach to sub-frame using provided 55mm socket head bolt and spacer.
10. Reinstall right side number plate.
11. Double check all work and that fasteners are tight.
12. 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.

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 center stand or ideally a service lift during installation. Be sure to save all stock components for possible use later.

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.

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.
P o lished 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 at the first signs of packing material deterioration. Part #005-10038 Repack all off road 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.

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>