How do I install the Two Brother Racing DR650 exhaust system on my Suzuki motorcycle? (Two Brother Racing DR650 1998-05 Suzuki Instruction Manual)

Answer

manuals.plus

Feb 27, 2025 - 06:46 AM

To install the Two Brother Racing DR650 exhaust system on your Suzuki motorcycle, please follow the instructions provided in the manual. Here is a step-by-step guide:

1. Ensure that 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.

2. Remove the right side number plate.

3. Remove the plate to access the joint clamp.

4. Loosen the joint clamp.

5. Remove the three OEM mounting bolts. One bolt will be used with the TBR system. Remove the OEM muffler assembly.

6. Attach the slip-tube using the provided hook springs.

7. Slide the TBR slip-tube into the OEM header. The OEM gasket will be used with the TBR system. Tighten the joint clamp.

8. Install the OEM bolt to mount the TBR slip tube. Re-install the OEM cover plate and tighten the mounting bolts.

9. Slide the muffler clamp over the S1R muffler and attach it to the sub-frame using the provided 55mm socket head bolt and spacer.

10. Reinstall the right side number plate.

11. Double-check all work and ensure that all fasteners are tight.

12. Before running 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.

13. 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.

14. Check for gaps or leaks. If you find a leak, a little high-temperature silicon sealant should fix it.

15. After 50 to 100 miles, recheck all fasteners for tightness.

Please note that it is recommended to have this performance part installed by a qualified motorcycle technician. If you have any doubts about your ability to install the exhaust system, it is advised to consult with your local motorcycle dealer.