Mfg: Suzuki Make: Bandit 1200 Year: 1997-2000 Product: Flange-On Exhaust System
IMPORTANT - PLEASE READ CAREFULLY 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 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 the sidestand or ideally a rear service stand during installation. Be sure to save all stock exhaust components for possible use later. Installation Instructions 1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on the sidestand or ideally a rear service stand. 2. Remove the nuts/bolts 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. You will reuse the stock flange gasket. 3. Install the canister with the gasket onto the end of the stock exhaust flange (the TBR badge faces to the outside). Youll have to hold it in place while you start the nuts/bolts through the flange holes and into the inlet. Go ahead and tighten evenly and fully. 4. 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.) Locate both tabs of the canister clamp on the outside of the passenger footpeg bracket. Use the stock hardware to secure it. 5. 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.

Parts List

Qty. 2 Description Muffler Canister (flange-on, right exit) Canister Clamp with Rubber Liner HARDWARE KIT 8 x 20mm Socket Head Bolt 8mm Washers Permatex Ultra Black Gasket Maker Two Brothers Racing Stickers Part Number Varies Varies 005-75-3 005-SH820 005-WF8 031-P22072 015-10208-A

Canister Clamp Detail

Care & Cleaning / Warranty
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. Chrome Header System: Chromed header tubing will turn blue close to the exhaust ports, this is normal. To prevent corrosion you must keep the header pipes clean. 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 mufflers 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 Mothers to restore the bright finish to factory spec. 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.

Bandit 1200 Flange-On Instructions.qxd

Installation guidelines for: Suzuki Bandit 1200 & 1250S (This is a weld-on kit and requires good mechanical skills). 1) Due to the frame configuration of this bike, this is one of the few kits that requires welding. The welding portion is a very simple operation but should be done by a qualified welder. See your dealer for matching frame paint, if desired. The effort youre going to make for this weld-on installation is well worth the results received from the stabilizer. 2) This kit is designed to be used with the upright style handlebars that comes stock on this model. 3) When welding, we you must remove the gas tank and store in a safe place well away from the welding area. Its a good idea to cover the gas tank with a large towel or protective pad so you dont scratch the tank while working on the bike. Standard welding rod works fine. Weld areas must be clean. Be sure to protect any flammable areas from the heat of welding. 4) Remove the 4 bolts that hold the handlebars tight with a 6mm Allen wrench (there may be small caps covering the Allen head bolts, you must be remove the covers before you can access the bolts. A knife or sharp edge can be slipped under the covers to help remove them. Discard your stock upper barclamp(s), you will not use them for this installation. 5) Install the Scotts, one-piece handlebar clamp, with the part #s toward the front of the bike, (see photo). 6) Tighten the 4 Allen head bolts in the barclamp evenly so the gap between the upper and lower perches is the same or equal. 7) Install the stabilizer to the barclamp using the (2) 6x20 Allen head bolts provided in the kit. 8) The stabilizer link arm is going to serve as the guide and holder for the frame bracket as you weld it in place. 9) Position the weld-on tower up under the linkarm and position it so it clears the tank and triple clamp (see photo). The tower is pre-cut to the approximate length for this kit, but each bike will vary slightly and we suggest you shape the bottom of the weld-on tower to suit your individual bikes frame. The more area you provide for welding to, the stronger the installation. You can file or grind the bottom where it welds to the frame for specific fitment purposes. The most common method is to provide bead of weld all the way across the backside of the weld-on tower. Remove the plating wherever welding will occur. 10) Be sure you are welding to a sturdy piece of the frame and not just a cosmetic cover area. Reinforcement is required on some. 11) With the weld-on tower aligned, be sure the linkarm is straight with the backbone of the bike. It is ideal to have the tower pin in the center of the slot in the link arm. Tack-weld the bracket in place. The linkarm should be straight when the bike is aimed straight ahead as in the photos below. Once this is verified, finish welding across the base of the tower. 12) The tower pin should be kept greased inside the tower hole. It is designed to float and requires no retaining devices. 13) Read your damper manual for initial settings on the controls. A separate page describes each valving circuit control. The stabilizer is infinitely adjustable and totally up to the user to find their preference. Start with softer (counter clockwise) settings. The base valve (the one with the pointer) controls the immediate feel of damping forces exerted. 14) If you have any questions on anything call us, we want to help you! B
Suzuki Bandit 1200/1250 weld-on instructions 02/04/10 29-0055