Installation instructions www.akrapovic.com Akrapovič Exhaust System: for the

Installation instructions www.akrapovic.com Akrapovič Exhaust System: for the
Installation instructions
Akrapovič Exhaust System:
Racing
for the
YAMAHA YZF-R25
YAMAHA YZF-R3
*504503*
www.akrapovic.com
www.akrapovic.com
Congratulations on purchasing an Akrapovič exhaust system. Please read the entire installation manual
prior to undertaking any activities related to installation of your new Akrapovič exhaust system. In case
you do not fully understand the manual or any of its parts, please contact your authorized dealer!
This product should be installed by someone with sufficient knowledge of exhaust systems and their
installation, and appropriate hand or power tools. If you are not qualified for this work, please utilize a
certified mechanic for installation. By installing Your Akrapovič exhaust system, you indicate that you
have read the installation manual in its entirety and you agree with the terms stated herein.
It is your responsibility to follow all installation instruction guidelines supplied with the Akrapovič exhaust
system and undertake all necessary safety precautions. Akrapovič d.d. assumes no responsibility for
damages occurring from misuse, abuse, improper installation, improper operation, lack of responsible
care, or all previously stated reasons resulting from incompatibility with other manufacturer’s products
and/or systems.
IMPORTANT INFORMATION
Exclusion of Certain Liability
1. The manufacturer, importer or dealer shall not be liable for any incidental damage including personal injury
or any other damages caused by improper installation or operation of the Akrapovič exhaust system. When
installing the Akrapovič exhaust system be careful that the exhaust system does not touch other parts
sensitive to high temperature.
2. Akrapovič makes no representation or warranties with regard to damage caused by the improper installation,
use and maintenance of the Akrapovič exhaust system. The warranty is limited to defects recognized by
our technical department and due to normal use, and excludes items subject to normal wear (gaskets and
damping wool). The guarantee is void in case of accident, modification, improper or competition use.
3. Do not attempt to install the Akrapovič exhaust system on a vehicle model for which it was not made or
tested by Akrapovič.
4. When the exhaust system gets very hot during operation, be careful not to burn yourself on the exhaust
system or parts which are in direct contact with it, even when the engine is not running. Also protect other
people, especially children, from the injuries mentioned above.
5. In some cases Akrapovič exhaust system kits contain chemical products (ceramic anti-seizing grease; bolt
sealant). Handle with care, do not inhale or swallow. Avoid excessive contact with skin, eyes or mucous
membranes. Keep out of reach of children.
6. Technical specifications of Akrapovič exhaust systems and related products are subject to change without
notice.
7. Before removing the original exhaust system from your vehicle, please compare the parts you received
with the list of materials provided in the installation manual in order to assure that you have all the parts
necessary for the installation of your new Akrapovič exhaust system.
8. Although this manual consists of instructions for installation in written form, as well as photographs and
pictures representing individual steps of the installation, please note that the photographs and pictures
are symbolic and are intended for representation of general overview only. The photographs and pictures
contained herein should serve as a guideline only and actual installation of the exhaust system may not
correspond with the photographs and pictures entirely.
9. The process of uninstalling the original exhaust system may vary depending on the existing exhaust system.
Please follow the original exhaust system manufacturer’s instructions for uninstalling the original exhaust
system.
Trademarks
The Akrapovič trademark, including corporate logos and emblems, are subject to copyright as well as trademark rights of Akrapovič, its licensors or third persons authorizing Akrapovič to use them.
Akrapovič website
Information about Akrapovič exhaust systems and related products is available on the Akrapovič website at:
http://www.akrapovic.com/
Copyright
No part of the Akrapovič exhaust system or its documentation may be reproduced or distributed in any form or
by any means without the prior written authorization of the Akrapovič company.
© Akrapovič, d.d. All rights reserved.
2
Symbols
The following symbols are used throughout these installation instructions:
TOOLS REQUIRED
TIGHTENING TORQUE
INSTALLATION TIP
CAUTION OR WARNING
USE BOLT SEALANT; Apply 3 to 4 small drops of bolt sealant onto the cleaned and degreased threads
before tightening the bolts. WARNING! Avoid contact with skin, eyes and mucous membranes.
Do not inhale fumes. Keep out of reach of children.
USE ANTI-SEIZE LEAD-FREE COPPER PASTE (black tube); Provides trouble-free and long-lasting
protection against seizing, corrosion and rusting of bolts, threaded ends, nuts, joints, etc. Also protects
against vibration, wear and impact. WARNING! Avoid eye contact. Avoid excessive skin contact.
Keep out of reach of children.
USE ANTI-SEIZING GREASE (white tube); Prevents seizing, corrosion and excessive wear between
the titanium components of your exhaust system. WARNING! Avoid eye contact. Avoid excessive
skin contact. Keep out of reach of children.
T-handle 4 mm wrench
T-handle 6 mm wrench
T-handle 12 mm wrench
Combination 12 mm wrench
Combination 13 mm wrench
T-handle 12 mm swivelling three hexagon
wrench
Torx 45 wrench
Spring-puller
BEFORE INSTALLING, CHECK THE PARTS LIST AND SCHEMATIC DRAWING OF THE EXHAUST
SYSTEM! THE LATEST VERSION OF THE PARTS LIST AND SCHEMATIC DRAWINGS OF THE
PRODUCTS ARE AVAILABLE ON OUR WEB PAGE.
IF ANY ITEMS IN THE AKRAPOVIČ EXHAUST SYSTEM PACKAGE ARE MISSING, PLEASE
CONTACT YOUR AUTHORIZED DEALER. KEEP THE SCHEMATIC FOR FUTURE REFERENCE.
THESE INSTALLATION INSTRUCTIONS MUST BE READ CAREFULLY IN ORDER TO ENSURE
PROPER INSTALLATION AND OPERATION OF THE AKRAPOVIČ EXHAUST SYSTEM.
THE EXHAUST SYSTEM CAN BE EXTREMELY HOT. ALLOW THE EXHAUST AND ENGINE TO
COOL DOWN BEFORE BEGINNING INSTALLATION.
WE ADVISE YOU TO LEAVE INSTALLATION TO A QUALIFIED SERVICEMAN. IMPROPER
INSTALLATION MAY RESULT IN A SHORTER LIFETIME OF THE EXHAUST SYSTEM AND/OR
DAMAGE TO THE VEHICLE.
THIS MANUAL IS SPECIFIC TO THE YAMAHA YZF-R3 2015. THERE MAY BE SOME DIFFERENCES
IN INSTALLATION PROCEDURES FOR OTHER MODELS.
AKRAPOVIČ MAKES EVERY EFFORT TO PROVIDE IMPROVED CORNERING CLEARANCE
FOR EXHAUST SYSTEMS. HOWEVER, DUE TO DESIGN AND SPACE LIMITATIONS ON SOME
MOTORCYCLE MODELS, GROUND AND CORNERING CLEARANCE MAY NOT IMPROVE OR
MAY EVEN BE REDUCED. FOR ADVANCED USERS, WE RECOMMEND INCREASING THE
SPRING PRELOAD SETTINGS TO IMPROVE GROUND CLEARANCE.
THE AKRAPOVIČ WARRANTY DOES NOT COVER DISCOLORATION OF ANY CHROME
PRODUCTS.
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REMOVAL OF STOCK EXHAUST SYSTEM:
1.
2.
Put the motorcycle on a central stand. Make sure, that surface is solid and flat.
Unscrew marked bolts and carefully remove black plastic cowling off the motorcycle (Figure 1).
WARNING: make sure not to scratch or damage any part of the motorcycle during this procedure!
Figure 1
3.
Unscrew muffler’s clamp and bracket bolt and carefully remove the muffler off the motorcycle (Figure 2, 3).
WARNING: make sure not to scratch or damage any part of the motorcycle or exhaust system during this
procedure!
Figure 2
4
Figure 3
4.
Unscrew marked lambda sensor, headers’ flange nuts, collector’s bolts and carefully remove the stock exhaust
system off the motorcycle (Figure 4, 5, 6).
WARNING: make sure not to scratch or damage any part of the motorcycle or exhaust system during this
procedure!
Figure 4
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Figure 5
LEFT SIDE
Figure 6
6
INSTALLATION OF THE AKRAPOVIČ EXHAUST SYSTEM:
1.
Install the Akrapovič headers onto the motorcycle and hand tighten the flanges onto the cylinder head (using stock nuts)
(Figure 7).
WARNING: do not fully tighten the flanges yet!
INSTALLATION TIP: use new stock exhaust port gaskets.
Figure 7
2.
Mount the press-on nut from Akrapovič installation kit onto the link pipe’s bracket, as shown (Figure 8).
Figure 8
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3.
Slide the link pipe onto the headers, attach the springs and tighten the bracket bolt, using bolt and washer from Akrapovič
installation kit. Tighten the lambda sensor into the link-pipe (Figure 9, 10).
WARNING: make sure not to damage the lambda sensor’s electrical lead during this process!
WARNING: use anti-seize copper paste only on the lambda sensor threads!
39Nm
29ftlb
22Nm
16ftlb
Figure 9
Figure 10
8
4.
Position the muffler correctly and slide it onto the outlet side of the link-pipe, attach the springs and hand tighten the muffler
bracket, using bolt, washers and nut from Akrapovič installation kit (Figure 11).
CAUTION: make sure, that springs pull the muffler all the way onto the collector – use rubber mallet if necessary
to tap the connection into place!
CAUTION: be careful not to damage the muffler or any part of the motorcycle during this process!
Figure 11
5.
Tighten header flanges to the specified torque (Figure 12).
22Nm
16ftlb
Figure 12
9
22Nm
16ftlb
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6.
Position the muffler in respect to the motorcycle and tighten bracket bolt to the specified torque (Figure 13).
22Nm
16ftlb
Figure 13
7.
Reinstall and tighten stock plastic cowling using stock bolts with specified torque (Figure 14).
WARNING: make sure not to scratch or damage any part of the motorcycle or exhaust system during this
procedure!
4.9Nm
3.6ftlb
4.9Nm
3.6ftlb
Figure 14
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Final installation:
Clean grease spots:
a. Muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant
(WD-40 or equivalent).
b. Muffler – carbon-fiber outer sleeve: use a soft dry cloth.
c. Muffler – carbon-fiber outlet cap: use a soft dry cloth.
d. Stainless steel pipes: use a soft cloth sprayed with a contact cleaner, then wipe with a
soft dry cloth.
e. Chrome plated parts: use a soft dry cloth.
f. Titanium pipes: use a soft cloth sprayed with a multi-purpose spray lubricant
(WD-40 or equivalent).
Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners,
because they can damage the sticker.
WARNING: make sure all the bolts are sufficiently tightened. In case the exhaust system touches
the cowling or other parts repeat the adjustment of the exhaust system or contact your authorized
dealer.
WARNING: after running engine for 30 minutes, retighten the bolts of the Akrapovic carbon-fiber
heat shield!
IT IS NORMAL IF WHITE SMOKE COMES OUT OF THE MUFFLER ON FIRST OPERATION.
DO NOT STAND BEHIND THE MUFFLER ON FIRST OPERATION.
DO NOT USE AUTOMOTIVE WHEEL CLEANERS OR ANY CLEANING PRODUCTS WHICH
CONTAIN ACIDIC ADDITIVES TO CLEAN AKRAPOVIČ EXHAUST SYSTEMS.
MAINTENANCE OF THE AKRAPOVIČ EXHAUST SYSTEM:
1. Clean the titanium exhaust components with a multi-purpose spray lubricant (WD-40 or equivalent),
carbon fiber exhaust components with soft and dry cloth and stainless steel components with soft cloth
sprayed with contact cleaner, then wipe with soft and dry cloth. A change in the color of the exhaust
system is normal due to the high temperatures.
2. Periodically make sure all the bolts and springs are sufficiently tight.
WARNING:
Please note that certain aftermarket exhaust systems may not comply with applicable California laws and
regulations, and may therefore be prohibited for use on California highways or roads, or on roads or vehicles
otherwise subject to emissions control requirements.
Akrapovič exhaust systems for automobiles and motorcycles mounted downstream of the catalytic converter (also
known as “cat-back systems”) are considered “replacement parts” in California by the California Air Resources
Board (CARB), and do not require an exemption or executive order from CARB to be sold in California. However,
California prohibits the use of any aftermarket exhaust system that modifies, removes or replaces original
equipment catalysts, unless CARB has issued an Executive Order as to such part or system.
Further, Akrapovič parts or exhaust systems used or intended for use on “racing vehicles” (i.e. a competition
vehicle used exclusively for competition on closed-course circuits) do not require an exemption or Executive
Order from CARB to be sold in California. However, such parts are prohibited from use on California public
highways or roads, even if occasionally used “off-road.”
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