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 muffler 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 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
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.
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
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.
