Two Brothers Racing 005-3860105-S1 User manual

8. Remove lower left and right fairings.
9. Remove front header cover.
10. Remove header pipes.
11. Using the OEM copper gasket between header collar and
cylinder head. Install TBR header using OEM bolts.
12. Remove lower rear set mounting bolt and replace with
supplied 8x40mm socket head cap screw.
Installation Instructions
1. Make sure the bike is completely cool before starting
the installation. Make sure the bike is secure on a center
stand or ideally a service lift.
2. Remove side covers and seat.
3. Remove rear passenger seat.
4. Remove OEM rear fender. You will reuse the fender bolts.
5. Remove rear exhaust cover.
6. Remove exhaust valve cables from servo under seat. Use
a wrench to hold server wheel in place or internal gears
may break.
7. Remove OEM mufer assembly.
Kawasaki
ZX-636
Full Exhaust System
Part # 005-3860105-S1
*Keep servo plugged
into harness but cables
will not be used.
IMPORTANT - PLEASE READ CAREFULLY
We recommend that this performance part be installed by a qualied 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 rst 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
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 nish to factory spec.
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 berglass packing inside is in good condition and not burned out, as exhaust
heat inside an empty canister will deteriorate the carbon ber sleeve.
TBR sells repack kits (Road - #005-10038, Offroad - #005-10038MX) that include everything you need to easily do
it yourself.
Titanium Mufers: For cleaning use a mild water based spray cleaner. Always apply cleaner or polish with a soft,
clean cloth. Always make sure the berglass packing inside is in good condition and not burned out, as exhaust
heat inside an empty canister will deteriorate the carbon ber 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 rst signs of packing material deterioration. Part #005-10038
NEVER dyno test your bike with carbon ber 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.

13. Attach the supplied mounting bracket to the inside of
frame and secure in place with the supplied 8mm ange
nut. Bracket should be installed as shown in picture.
14. Apply a thin layer of anti-seize to slip tube outlet and
attach TBR mufer using supplied hook springs. Install
barrel clamp onto slip tube.
15. Install rubber lined mufer clamp over canister. Mount
the slip-tube using the supplied 10mm nut and OEM
bolt.
16. Attach the TBR mufer assembly using the ange bolt
and nut to secure the mufer in place.
17. Check alignment and tighten mufer.
Installation Instructions
Qty. Description Part Number
1 S1R Canister Varies
1 Mufer Clamp Varies
1 Header 005-24101H
1 Slip Tube 005-38601S
1 Barrel Clamp 005-27-63MSH
1 Mufer Bracket 005-241-B
1 Fender Bracket 005-19904B
2 Lighted License Plate Bolt 005-8504LT2
1 Turn Signals (set of 2) 005-88T2
6 Butt Splice Connectors 005-BS1614
1 Zip Tie 005-ZT458B
1 Zip Tie Tab 005-ZTM4
1 8x40mm Socket Head Cap Screw 005-SH840
4 6mm Flange Nut 005-FN6
1 8x16mm Flange Bolt 005-FB816
2 8mm Flange Nut 005-FN8
1 10mm Nut 005-NN11
2 45mm Spring 005-S45
1 Spring Puller 005-SP
Left Turn Signal
(Grey connector)
Red
Plate Lights
Right Turn Signal
(Black connector)
Wiring Harness
Red
Black
Kawasaki
ZX-636
Full Exhaust System
Part # 005-3860105-S1
18. Tighten barrel clamp.
19. Install TBR fender eliminator kit using the original bolts
and supplied nuts, the nuts will be inside the bike under
seat.
20. Attach turn signals and plate light bolts using the wire
splice connectors supplied to the correct wires in the
harness as shown in the Wiring Diagram.
21. Re-install seats and covers.
22. Double check all your work.
23. Before you run the bike, clean off all ngerprints and
dirt, as any oily residue will etch the metal and become
somewhat permanent when the system gets hot. Also,
remove any plastic lm from the name badge(s) and or
canister clamp(s). Run the bike and enjoy. It is normal for
some white smoke to appear the rst time you start the
bike. This is packing/manufacturing oil from inside the
pipe burning off. Check for gaps or leaks. If you nd a
leak, a little high temperature silicon sealant should x it.
After 50 to 100 miles, recheck all fasteners for tightness.