Instruction Manual

1- Canister (slip-on, right exit)
1- Canister Clamp
(C2-C5 canister use offset clamp)
(C4 canister use standard clamp)
1- Stainless Steel Header
(# 005-2401N)
1- Stainless Steel S-Bend
2- Connector Springs (# 005-S80)
2- Connector Springs (# 005-S55)
1- Hanger Bracket
(# 005-2404HK, Rightside only)
1- T-Bolt clamp (64mm)
1- 8mm x 20mm Flange Bolt
1- 8mm Nylock Nut
2- 8mm Washer
1- 8mm x 35mm Bolt
1- 10mm Spacer
1- Packet of Hi-Temp Sealant
(# 031-P22072)
1- Packet of Anti Seize
(# 031-P09175)
Care & Cleaning
Keep system free of dirt and moisture. Store in a cool, dry place. For cleaning use a mild spray cleaner. Always
apply cleaner or polish with a soft, clean cloth.
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.
Chrome Header System: Chromed header tubing will turn blue close to the exhaust ports, this is normal. To pre-
vent corrosion you must keep the header pipes clean.
Carbon Fiber & X-Metal Mufflers: X-Metal CF canisters will shift color from their original silver color to an amber
color after a few heat cycles, similar to the way our stainless steel headers shift color. Always make sure the fiber-
glass packing inside is in good condition and not burned out, as exhaust heat inside an empty canister will deterio-
rate the Carbon Fiber / X-Metal CF sleeve. TBR sells repack kits (TBR part # 005-10038) that include new rivets
and repack material as well as a drill bit (#30), making it easy to do yourself. Also, NEVER dyno test your bike with
carbon fiber mufflers installed - the intense heat and lack of cooling air can quickly cause the CF material to burn.
Two Brothers Racing does not provide a warranty for burned carbon fiber.
Aluminum Mufflers: Use an aluminum or mag wheel polish such as Mother’s to restore the bright finish to factory
spec.
W
arranty
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 exhaust system
be installed by a qualified motorcycle technician. If you
have any doubts as to your ability to install this exhaust
system, please consult with your local motorcycle deal-
er. Read all instructions first before starting installation.
Make sure the motorcycle and exhaust system are com-
pletely cool before starting the installation. Also, make
sure the bike is secure on the sidestand or ideally a rear
service stand during installation. Be sure to save all
stock exhaust components for possible use later.
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. Loosen the four clamps (left and right side) that hold the
muffler connector pipe to the headers under the bike.
3. On the under side of the bike, remove the bolt holding
the main collector to the bike.
4. Remove the bolts that hold that stock mufflers on and
remove the stock mufflers from the bike. Remove the
stock headers.
5. Dry fit the headers first. Install the rear cylinder pipes all
the way into the front header assembly. Mark the depth
with a marker. This will give you a mark to aim for when
installing the headers on the bike.
6. Carefully pry out the old exhaust
port crush gaskets and replace
them with new gaskets. A small dab
of grease will hold them in place
while you mount the new header.
7. Apply anti-seize compound to the exhaust studs. Install
the rear cylinder pipes first. Leave loose for now.
8. Install the front header assembly, sliding it into the rear
cylinder pipes. Push the header on until you reach the
mark you made earlier. Don’t be afraid to tweak the pipes
slightly if they don’t go into the cylinder ports right away.
Leave loose for now. IT IS VERY EASY TO INSTALL
THE HEADERS INCORRECTLY, WHICH CAN RESULT
IN DECREASED GROUND CLEARANCE.
9. Place a bead of the hi-temp sealant on the outside edge
of the header that goes into the s-bend. Slide the s-bend
and t-bolt clamp onto the end of the header. Wipe off the
excess sealant that will squeeze out. Leave loose for
now.
10. Place a bead of the hi-temp sealant on the outside edge
of the s-bend that goes into the canister. Slide the TBR
canister onto the end of the S-bend pipe. Wipe off the
excess sealant that will squeeze out. Repeat on opposite
side.
11. Install the offset hanger brackets to the front of the seat
rail using the supplied 8mm x 35mm bolt, 8mm washer
and 10mm spacer.
12. Carefully slide the canister clamp over the muffler. (Note:
The stainless steel canister clamp and the name badge
on the canister come from the factory with a clear plastic
protective film. Please remove this film before operation.)
You may need to twist and turn the S-bend a little to get it
in the right place. Locate both tabs of the canister clamp
outside of the hanger bracket. Use the 8mm x 20mm
flange bolts, 8mm washers and 8mm nylock nut to
secure it. Leave loose for now.
13. Make sure everything is aligned and tighten all hardware.
Torque the front header nuts to factory spec. Affix the
connector springs to the mufflers (55mm on the headers,
80mm on the canister). Be sure that the hanger brackets
clear the shock. If not, readjust the system until it does
clear.
14. Before you run the bike, clean off all fingerprints and dirt,
as any oily residue will etch the metal and become some-
what 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/manufac-
turing 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.
IMPORTANT - PLEASE READ CAREFULLY
Canister Clamp Detail
V-Max Slip-On Instructions.qxd
OE Exhaust System
Installation Instructions
Care & Cleaning / Warranty
Parts List
Mfg: Yamaha Make: V-Max
Year: All
Product: Full Exhaust System
Top view of brackets
(note offset hole on
bottom portion)
Marker
Rightside, View
from rear of bike