Two-brothers-racing Kawasaki ZRX1200 Bedienungsanleitung PDF herunterladen

Kawasaki ZRX1200

Flange-On Exhaust System

Parts List

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. Remove the flange cover at the front of the canister by

unscrewing bolts that are found inside holes in the cover.

You will be re-using this cover.

3. Remove the nuts holding the stock canister onto the

flange. Loosen the hardware that holds the canister to

the passenger footpeg and remove the canister from the

bike.

4. If your bike has the pipe extending past the flange you

will need to trim it. This will not affect refitting the stock

canister if you ever need to. Be sure to measure twice

and cut once! Typically you can leave 1/2” of pipe

extending past the flange face.

5. Install the canister onto the end of the stock exhaust

flange (the TBR badge faces to the outside). You’ll have

to hold it in place while you start the 8mm x 20mm bolts

through the flange holes and into the inlet. Go ahead and

tighten evenly and fully.

6. Install the hanger bracket to the passenger footpeg

bracket using the stock hardware. The bracket should

point backward and down toward the canister. Leave

loose for now.

7. Carefully slide the canister clamp over the canister.

(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.) Locate both tabs of the canister clamp on the

outside of the hanger bracket. Use the 8mm x 20mm

bolt, washers and nut to secure it. Leave loose for now.

8. Make sure everything is aligned and tighten all hardware.

Reinstall the flange cover.

9. 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

ZRX1200 Flange-On Instructions.qxd

Installation Instructions

Canister Clamp Detail

1/2”

QTY. DESCRIPTION PART NUMBER

1 C4 MUFFLER (17.5”, RIGHT SIDE, FLANGE # E115) VARIES

1 C4 MUFFLER CLAMP VARIES

1 HARDWARE KIT 005-74-3

4 8X20MM SOCKET HEAD CAP SCREWS 005-SH820

6 8MM FLAT WASHER 005-WF8

1 8MM NYLON LOCK NUT 005-NN8

1 MUFFLER BRACKET 005-17B

2 TWO BROTHERS RACING DECALS 015-10208-A

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.

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 fiberglass packing inside is

in good condition and not burned out, as exhaust heat inside an empty canister will

deteriorate 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 muf-

flers 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.

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 dis-

claims all responsibility for consequential and incidental damages or any other losses

arising from the use of these products or parts.

Care & Cleaning / Warranty

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Seite 1 - Flange-On Exhaust System

Kawasaki ZRX1200Flange-On Exhaust SystemParts ListWe recommend that this performance exhaust systembe installed by a qualified motorcycle technician.

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Two-brothers-racing Kawasaki ZRX1200 Bedienungsanleitung

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