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These are the instructions you need to install a TBR slip-on exhaust on a Honda 919. The same basic procedures can be used for both the dual and single slip on exhausts. For information on purchasing a slip on exhaust, go to the Two Brother’s Racing Website.
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.
- 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.
- Remove the grab rail, seat and tail section.
- Remove the 6mm x 10mm bullonhead bolts from the underside of the rear fender (see picture).
- Loosen the clamps that hold the stock canisters at the “Y” connector pipe. Remove the stock mufflers.
- You will need raise and support the rear of the motorcy cle and remove the rear shock in order to remove the “Y” connector pipe. The rear shock must be removed in order to remove the “V” connector pipe from the motorcycle.
- After removing the “Y” connector pipe reinstall the rear shock. Be sure to torque all bolts to factory specifications.
- Replace the stock rear brake line with the stainless steel line provided. The new brake line does not follow stock routing. Be sure the brake line does not touch the exhaust system.
- Install the new TBR bracket on the underside of the rear fender (see picture) using the supplied 6mm x 20mm bolts.
- 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 onto the end of the header. Wipe off the excess sealant that will squeeze out. Use the stainless steel T-bolt clamp to secure it. Leave loose for now.
- 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.
- 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.) You may need to twist and turn the S-bend a lillie to get it in the right place. Locate both tabs of the canister clamps toward the inboard and underside of the rear fender. Use the 8mm x 16mm hardware to secure the clamps. Leave loose for now.
- Make sure everything is aligned and tighten all hardware. Some tweaking may be required for proper alignment. Be sure you have proper clearances between the exhaust system and the motorcycle. Affix the connector springs to the muffler.
- Reinstall the grab rail and tail section. Be sure to check the operation of the key prior to reinstalling the seat as the lock mechanism can easily be jammed during seat cowl installation. DO NOT INSTALL SEAT IF KEY CAN NOT BE REMOVED FROM LOCK MECHANISM. Reinstall seat only after lock works properly.
- Be sure to allow the sealant to dry per the manufacturer’s instructions before starting the bike. 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 lillie high temperature silicon sealant should fix it. After 50 to 100 miles, recheck all fasteners for tightness.
Bracket Detail:
Underside Detail:
Finished Product:
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