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BMW K1200 RS/ GT Full Exhaust System Full Exhaust System Installation Manual

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Filed Under (BMW) by admin on 26-10-2010

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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 lower fairing. 3. Unscrew the O 2 sensor. Remove the stock exhaust system at the rear canister support bracket and where it bolts to the engine. CAUTION -the stock exhaust is very heavy, be careful not to drop it! Also, be careful not to damage the engine sensor located near the front header pipe. 4. Pry out the old exhaust port gaskets and replace with new BMW OE (x4) exhaust port gaskets. Adab of grease will help hold the gaskets in place while you work. 5. Coat the exhaust studs and O 2 sensor threads with high temperature anti-seize compound. 6. Install the TBR headers into the exhaust ports making sure to get a good seat onto the exhaust port gaskets. Next, install the header nuts starting at the rear/outside stud and working your way forward on the outside set of studs. Once that is finished repeat along the inside set of studs. Tighten header nuts only finger tight at this point. 7. Be sure to coat the threads of the sensor with the included packet of hi-temp anti-seize. Install the O 2 sensor into the TBR headers. Turning the sensor in the counterclockwise direction a few times then screwing it clockwise to install will help make it easier to install and prevent the wire from binding. 8. Place a bead of the hi-temp sealant on the outside edge of the headers 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. 9. Carefully slide the muffler 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.) Attach it to the canister support bracket using the stock BMWhardware. Both tabs of the canister clamp should be located on the inside of the canister support bracket. Leave loose for the moment. 10. Make sure everything is lined up and start to evenly tighten up the header nuts to BMWfactory torque specification. Tighten the canister support hardware and install the springs as well. 11. Start the bike and check for leaks around the exhaust ports and the header/canister junction. 12. Reinstall the lower fairing

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2008-2009 HONDA CBR 1000 RR DUAL CANISTER SLIP-ON INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 22-11-2011

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INSURE THE EXHAUST SYSTEM AND EXHAUST COMPONENTS ARE FULLY COOLED. 2. INSURE THE MOTORCYCLE IS STABLE ON KICKSTAND OR REAR CENTERSTAND OR SERVICE TABLE. 3. REMOVE THE 3 PLASTIC BUTTONS HOLDING THE PLASTIC COVER OVER THE EXHAUST SERVO. (THIS IS LOCATED DIRECTLY INSIDE THE RIGHT REAR PASSENGER PEG BRACKET) DETACH THE CABLE END FROM THE SERVOnWHEEL AND REMOVE THE ENTIRE CABLE FROM THE RETAINING CLIP. THE ENTIREnCABLE WILL NOW REMOVE WITH THE REST OF THE EXHAUST.REPLACE THE PLASTIC COVER FOR THE SERVO AND REINSTALL THE 3 PLASTIC BUTTONS. 6. REMOVE THE STOCK MUFFLER MOUNTING BOLT. REMOVE 7. REMOVE THE STOCK EXHAUST CLAMP. (IT IS NOT UNCOMMON FOR THE CLAMP BOLT TO BREAK DURING REMOVAL.)b8. REMOVE THE ENTIRE STOCK EXHAUST ASSEMBLY. BE CAREFUL NOT TO SCRATCH THE SWING ARM DURING REMOVAL. 9. REMOVE THE STOCK EXHAUST GASKET FROM HEADER PIPE IF IT DID NOT COME OFF WITH THE STOCK EXHAUST. THIS GASKET WILL
NOT BE USED. 10. PREASSEMBLE THE HYPERFLO EXHAUST BEFORE INSTALLING. HYPERFLO RECOMMENDS YOU DO THIS PORTION ON CARPET OR A CLEAN PADDED AREA. YOU MAY ALSO USE THE PLASTIC BUBBLE PACKAGING AS A PAD TO PROTECT THE CANISTERS DURING PREASSEMBLY. 11. PREASSEMBLE THE LARGE DIAMETER CAN TO THE S-PIPE FIRST. INSTALL THE SPRING ON THE CANISTER FIRST AND PULL AWAY FROM THE CANISTER TO INSURE YOU DO NOT SCRATCH THE CANISTER

Aprilia Mille And Mille R Exhaust System Installation Instructions

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Filed Under (Aprilia) by admin on 26-10-2010

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1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on the sidestand or ideally a service lift. 2. Unhook the springs holds the stock canister to the headers under the bike. 3. Remove the hardware that holds the stock canister at the exhaust bracket. Take off the stock canister. 4. Install the new s-bend into the stock header. 5. Install VALE adapter kit using supplied kit instructions. 6. 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. 7. Carefully slide the muffler 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 on the outside of the exhaust bracket. Use the stock hardware to secure it. Leave loose for now. 8. Make sure everything is aligned and tighten all hardware. Reinstall the stock springs at the s-bend/header junction. Affix the two connector springs to the muffler. 9. 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

BMW F650GS / F800GS Slip-On Exhaust System with M-2 Exhaust Canister Installation Instructions

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Filed Under (Yamaha) by admin on 09-11-2010

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1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on a centerstand or ideally a service lift. 2. Remove muffler joint springs, set aside to re-use later. 3. Remove muffler mounting bolt and decorative washer, set aside to re-use washer later. 4. Attach TBR slip tube to TBR muffler using the 2 piece X-Rings and 6x14mm socket head cap screws with lock washer that are provided. Leave loose enough to make some adjustments on the motorcycle. 5. Attach muffler assembly to motorcycle using the OEM springs and supllied muffler clamp. Use the supplied 8x20mm socket head cap screw and OEM washer to secure muffler clamp. *a small amount of high temp silicone on slip joint may be used. 6. Align muffler and tighten the 4 X-Ring bolts. 7. Double check your work to ensure everything is tight and properly installed. 8. 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. 2008-09 BMW F650GS / F800GS V.A.L.E.™ Slip-On Exhaust System with M-2 Exhaust Canister Part # 005-2630406V / 005-2630407V / 005-2630408V Qty. Description Part Number 1 M-2 Muffler Canister Varies 1 Slip-On Tube Assembly 005-26304S 1 Muffler Clamp Varies 1 HARDWARE KIT 005-263-3 2 X-Ring (half) 005-7-2-3 4 6x14mm Socket Head Cap Screw 005-SH614 4 6mm Split Washer 005-WL6 1 8×20 Sockey Head Cap Screw

KYMCO Super 8 150 Exhaust System with M-2 Canister Installation Instructions

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Filed Under (Kymco) by admin on 26-10-2010

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1.*Make*sure*the*bike*is*completely*cool*before*starting* the*installation.*Make*sure*the*bike*is*secure*on*a* centerstand*or*ideally*a*service*lift. 2.*Remove*OEM*exhaust*assembly. 3.*Attach*supplied*muffler*hanger*bracket*using*the* supplied*flange*bolts*and*tighten*to*15lbs-ft. 4.*Attach*TBR*header*to*muffler*using*the*X-ring*and*4* 6x14mm*bolts*with*lock*washers*provided,*leave*loose* for*now. 5.*Install*TBR*exhaust*to*scooter*keeping*the*OEM*exhaust* gasket*between*header*and*cylinder*head. 6.*Slide*rubber*lined*muffler*clamp*over*muffler*assembly* and*secure*to*bracket*using*supplied*8x20mm*bolt*and* nut. 7 .*Check*muffler*alignment*and*tighten*header*nuts*then* X-ring*bolts*and*finally*muffler*clamp*bolt. 8.*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. Qty.*Description* Part*Number 1* Muffler*Canister*M-2** Varies 1* Header* 005-27401H 1* Muffler*Clamp* Varies 1* HARDWARE*KIT* 005-274-3 2* *X-Ring* (half)* 005-7-2-3 1* *Long*Muffler*Mounting*Bracket* 005-274-B 1* *8mm*Flange*Nut* 005-FN8

2007-2010 HONDA CBR 600RR DUAL CANISTER SLIP-ON INSTALLATION

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Filed Under (Honda) by admin on 10-12-2011

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Hyperflo must insist that this system be used for track and closed course use only. Professional installation is recommended. Before beginning installation, please insure your motorcycle exhaust and omponents are not hot and have had ample time to cool. Please insure the motorcycle has been secured properly and is on level ground. We recommend the use of a service table. Hyperflo offers professional installation help at 801.999.8183. • 2 CARBON FIBER CANISTERS
• 2 END TIPS  (Options: Classic or Billet Stylewith sound cores) • MIDPIPE • 2 SPRINGS • 1 CLAMP
• UPPER MOUNTING BRACKET WITH BLINKERS ATTACHED • LOWER MOUNTING BRACKET WITH TAIL LIGHT AND PLATE MOUNTS • BRACKET BOLT (8MM X 75MM 1.25T) • EXTRA STICKERS • 8 TERMINAL ENDS/BUTT SPLICES 20072010 HONDA CBR 600RR DUAL CANISTER SLIPON INSTALLATION INSTRUCTIONS IMPORTANT! PLEASE READ PARTS LIST
YPERFLO RECOMMENDS THAT YOU LABEL SMALL PLASTIC BAGGIES TO KEEP HARDWARE SORTED AS IT IS REMOVED.
HARDWARE SORTED AS IT IS REMOVED. 1. INSURE THE EXHAUST SYSTEM AND EXHAUST COMPONENTS ARE FULLY COOLED. 2. INSURE THE MOTORCYCLE IS STABLE ON KICKSTAND OR REAR TIRESTAND OR SERVICE TABLE. 3. REMOVE BOTH THE FRONT AND REAR SEATS. 4. REMOVE THE 4 BOLTS HOLDING THE TAIL FAIRING TO THE SUBFRAME AND REMOVE THE TAIL FAIRING. REMOVE 5. REMOVE TRIM PLASTIC JUST ABOVE RIGHT SIDE FOOTPEG. (REMOVE THE ONE BOLT AND UNCLIP) TRIM PLASTIC UNCLIP REMOVE 6. REMOVE LOWER FOOT PEG BRACKET AND REMOVE THE HEAT SHIELD BOLT. ALLOW THE FOOT PEG BRACKET TO HANG BY THE HOSE AND WIRES. REMOVE 7. REMOVE THE PASSANGER FOOT PEG BRACKET ON THE RIGHT SIDE.

Ktm 690 SM/ SMC/ SMR/ Duke Removal and Installation weld slag

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Filed Under (KTM) by admin on 04-03-2012

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1. Each bike varies with regard to welds and gussets. Review the photos first to get the idea of what needs to be done. 2. These photos may not be your exact model but depict the concept of what must be done. 3. Block the front tire securely before removing the top triple clamp so the tire cannot move at all. See photos. 4. Support the rear tire also, just enough to keep tension on the front tire so the forks stay tight. 5. Warning: Once the triple clamp is loose, the forks can roll away from the bike AND it happens very quickly . 6. The main triple clamp nut adjusts the tension on the steering head bearings. Make note of its tension before removing and do not over tighten the nut. It should be seated just enough to take the play out of the bearing.. 7. The top of the gauge/light cluster is mounted to the top triple clamp. You have to take out 4 self tapping Phillips head screws to remove the gauge pod. There is one connector on the back side of that and then it comes off. Then there are two bolts that need to come out with an 8mm wrench to free the top triple clamp. 8. Loosen the triple clamp pinch bolt under the main nut and forks pinch bolts and remove the top triple clamp, taking note of how tight the main nut is, so you can re-tighten it to the exact amount. Remove the tin bearing shroud (cover) and rubber seal making note of how the seal goes on, (lips face downward). 9. Grease your bearings while you have them exposed. (Keep the grease off the area where our frame bracket mounts!). 10. The goal is to allow the frame bracket to clamp cleanly and squarely around the upper half of the head tube. 11. Review your individual bike’s welding characteristics at the head tube. You’ll notice on the head tube there is a “groove” machined 360 degrees around the head tube. Everything in or above this groove must be clean of welds or slag. If this groove is visible all the way around and no welding slag has extended upward into or past this groove, then you’re installation should be easy. Any welds extending into or above this groove must be filed away, but without changing the clamping area diameter. DO NOT file away the paint on the clamping area if possible. Spend a little more time filing carefully and your bracket will stay tight. 12. Each bike seems to have not only different welds, but slightly different gussets. Evaluate your individual bike to determine the best fit. The bracket must clamp squarely and cleanly to the area just above that groove and yet SIT FLUSH all the way around the diameter of the head tube as per the photo in the lower right corner. Do not allow the bracket to protrude above the seal seating surface. Use a flashlight to see up under the bracket where it’s hitting if it’s not Flush. This bracket has clearance cut into it to clear the backbone of the frame

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2007-2008 HONDA CBR 600RR DUAL CANISTER SLIP- ON INSTALLATION

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Filed Under (Honda) by admin on 04-12-2011

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INSURE THE EXHAUST SYSTEM AND EXHAUST COMPONENTS ARE FULLY COOLED. 2. INSURE THE MOTORCYCLE IS STABLE ON KICKSTAND OR REAR CENTERSTAND OR SERVICE TABLE. 3. REMOVE BOTH THE FRONT AND REAR SEATS. 4. REMOVE THE 4 BOLTS HOLDING THE TAIL
FAIRING TO THE SUBFRAME AND REMOVE THE TAIL FAIRING. REMOVE 5. REMOVE TRIM PLASTIC JUST ABOVE RIGHT SIDE FOOTPEG. (REMOVE THE ONE BOLT AND UNCLIP) TRIM PLASTIC UNCLIP REMOVE 6. REMOVE LOWER FOOT PEG BRACKET AND REMOVE THE HEAT SHIELD BOLT. ALLOW THE FOOT PEG BRACKET TO HANG BY THE HOSE AND WIRES

BMW F650 GS Single Slipp-On Exhaust System Installation Manual

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Filed Under (BMW) by admin on 26-10-2010

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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 stock exhaust canisters. 3. Install the 90obracket on the left side of the bike per the photo. Reuse the stock torx bolt to secure. 4. Place a bead of the hi-temp sealant on the outside edge of the header that goes into the S-bend. Slide the barrel clamp onto the end of the s-bend (the end with the slots cut into it). Slide the S-bend and barrel clamp onto the end of the header. Wipe off the excess sealant that will squeeze out. 5. 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. 6. Carefully slide the muffler 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 90obracket. Use the 8mm x 20mm flange bolt and 8mm nut &washer to secure it. Leave loose for now. 7. Make sure everything is aligned and tighten all hardware. Affix the connector springs to the muffler. 8. 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

2002 Triumph Speed Triple 955i Standard Mount Slip-On Exhaust System Installation Instructions

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Filed Under (Triumph) by admin on 29-10-2010

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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 clamp that holds the muffler connector pipe to the headers. 3. Remove the hardware that holds the stock muffler at the passenger footpeg bracket. Take off the muffler. 4. Place a bead of the hi-temp sealant on the outside edge of the header that goes into the s-bend. Wipe off the excess sealant that will squeeze out. Slide the S-bend connector pipe onto the end of the headers (wipe off the excess sealant that will squeeze out). Re-use the stock clamp to attach the s-bend to the headers. Leave loose for now. 5. 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. 6. Carefully slide the muffler 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 and the 50mm spacer on the inside of the passenger footpeg bracket. Use the 85mm bolt and stock nut & washer to secure it. Leave loose for now. 7. Make sure everything is aligned and tighten all hardware. Affix the connector springs to the muffler. 8. 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.

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