Installation instructions: AKRAPOVIC SLIP-ON EXHAUST

Installation instructions:
*502180*
AKRAPOVIC SLIP-ON EXHAUST SYSTEM
for the
Kawasaki Ninja ZX-6R
Kawasaki 636 Ninja ZX-6R
Congratulations on purchasing an Akrapovic exhaust system. Please read these installation instructions carefully. If
you have any trouble installing the system please contact your authorized dealer!
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 Akrapovic exhaust system. When installing the
Akrapovic exhaust system be careful that the exhaust system does not touch other parts sensitive to high
temperature.
2.
Akrapovic makes no representation or warranties with regard to damage caused by the improper installation, use and
maintenance of the Akrapovic exhaust system. The warranty is limited to defects recognized by our technical
department and 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 Akrapovic exhaust system on a motorcycle for which it was not made or tested by
Akrapovic.
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 motor is not running. Also protect other people, especially
children, from the injuries mentioned above.
5.
In some cases Akrapovic 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 Akrapovic exhaust systems and related products subject to change without notice.
Trademarks
The Akrapovic Exhaust System Technology logo is a registered trademark of Akrapovic d.d.
Akrapovic website
Information about Akrapovic exhaust systems and related products is available on the Akrapovic website at:
http://www.akrapovic.com/
Copyright
No part of the Akrapovic exhaust system or its documentation may be reproduced or distributed in any form or by any
means without the prior written authorization of the Akrapovic company.
 Akrapovic, d.d. All rights reserved.
Symbols
The following symbols are used throughout these installation instructions:
! CAUTION OR WARNING
TOOLS
REQUIRED
INSTALLATION TIP
TIGHTENING
TORQUE
USE BOLT SEALANT; Apply 3 to 4 small drops of bolt sealant onto the cleaned and degreased threads before
tightening bolts. WARNING! Avoid contact with skin, eyes and mucous membranes. Do not inhale fumes. Keep
out of the 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
the 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 the reach of children.
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INSTALLATION INSTRUCTIONS
BEFORE INSTALLING CHECK SCHEMATIC OF THE EXHAUST SYSTEM!
!
IF ANY ITEMS IN THE AKRAPOVIC 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 AKRAPOVIC EXHAUST SYSTEM.
!
THE EXHAUST SYSTEM CAN BE EXTREMELY HOT. ALLOW THE MOTORCYCLE 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 MOTORCYCLE.
T-handle 8 mm wrench
T-handle 10 mm wrench
T-handle 12 mm wrench
T-handle 10 mm swiveling wrench
T-handle 12 mm swiveling wrench
T-handle 4 mm three hexagon key wrench
T-handle 5 mm three hexagon key wrench
Combination 8 mm wrench
Combination 8 mm wrench
Combination 15 mm wrench
Spring puller
REMOVAL OF STOCK EXHAUST SYSTEM:
1.
2.
Put the motorcycle on a side stand, we recommend a racing stand. Make sure, that surface is solid and flat.
Unscrew and remove fuel tank side panels and rider’s seat (Figure 1, 2, 3, 4).
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Figure 1
Figure 2
Figure 3
Figure 4
2
3.
Slide the rubber protection off the cable adjusters (Figure 5). Loosen the nuts and shorten the adjusters (Figure 7).
WARNING: measure (Figure 6) or mark the distance on both adjusters so you can adjust them after installation of
Akrapovic exhaust system!
Figure 5
Figure 6
Figure 7
4.
For OPEN SLIP-ON only: remove the safety pin and cables from the exhaust valve servo motor (Figure 8, 9).
WARNING: do not turn the servo motor wheel with force (only by ignition key switching!) or the servo motor could
be damaged!
WARNING: do not remove or disconnect the servo motor!
Figure 8
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Figure 9
3
5.
Unscrev the bolts and remove the stock heat shield (Figure 10, 11).
Figure 10
6.
Figure 11
For STREET LEGAL SLIP-ON only: unscrew the nuts and remove both cables from the stock exhaust valve (Figure 12,
13). Unscrew the bolt from the metal clamp at the muffler - catalytic converter box joint and muffler sub-frame bracket and
remove the stock muffler (Figure 14, 15, 16).
WARNING: before removeing, mark the cables, so they can’t be swaped!
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Figure 12
Figure 13
Figure 14
Figure 15
4
Figure 16
7.
For OPEN SLIP-ON only: unscrew the bolt from the metal clamp at the muffler - catalytic converter box joint and muffler
sub-frame bracket. Remove the muffler together with exhaust valve cables (Figure 17, 18, 19).
WARNING: be careful not to damage the cables or any other part of the motorcycle during removal!
Figure 17
Figure 18
Figure 19
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5
8.
9.
For OPTIONAL LINK PIPE only: unscrew and remove the stock heat shield (Figure 20, 21, 22, 23).
Figure 20
Figure 21
Figure 22
Figure 23
For OPTIONAL LINK PIPE only: unscrew and remove the lower part of the cowling (Figure 24, 25, 26, 27, 28, 29).
Figure 24
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Figure 25
6
Figure 26
Figure 27
Figure 28
Figure 29
10. For OPTIONAL LINK PIPE only: loosen up the nuts of the header tube flanges so that you can remove the catalytic
converter box (Figure 30).
WARNING: make sure not to damage the cooling fins of the water cooler or any other part of the motorcycle!
Figure 30
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11. For OPTIONAL LINK PIPE only: unscrew the bolt from the metal clamp at the catalytic converter box - header tubes joint
and catalytic converter box bracket (Figure 31, 32). Remove the catalytic converter box.
Figure 31
Figure 32
INSTALLATION OF THE AKRAPOVIC SLIP-ON EXHAUST SYSTEM:
1.
For OPTIONAL LINK PIPE only: remove stock graphite gasket from stock collector and replace it with Akrapovic graphite
gasket (Figure 33). Coat the bolt and interior side of the metal clamp with Akrapovic anti-seize lead-free copper paste
(black tube) and correctly install the metal clamp and second graphite gasket into the link pipe (Figure 34, 35).
Figure 33
Figure 34
Figure 35
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2.
For OPTIONAL LINK PIPE only: slide the optional link pipe onto the stock collector and tighten the bolt of the link pipe
bracket using stock bolt with Akrapovic nut and washer. Tighten the stock metal clamp of link pipe/collector joint (Figure
36, 37, 38, 39). Reinstall the lower part of the cowling (Figure 40). Check vehicle manufacturer manual for tightening
torques (for dismounted stock parts).
Figure 36
Figure 37
34 Nm
25ftlb
21Nm
15ftlb
Figure 38
Figure 39
5.9Nm
4.3 ftlb
Figure 40
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3.
Remove stock graphite gasket and replace it with Akrapovic graphite gasket (Figure 41). Unscrew and remove stock
catalytic converter box heat shield (Figure 42, 43).
Figure 42
Figure 41
Figure 43
4.
Correctly install Akrapovic metal clamp with spring hook (Figure 44, 45). Reinstall the stock catalytic converter box heat
shield (Figure 46).
4.9Nm
3.6ftlb
Figure 44
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Figure 45
10
9.8Nm
7ftlb
Figure 46
5.
Correctly position the carbon-fiber clamp and slide it onto the muffler - bear in mind the left offset of the carbon-fiber
clamp viewed from the end of the muffler (position sticker saying TZ3 or CZ3 should be on the inner side of the muffler).
WARNING: open the clamp slightly wider than the diameter of the outer sleeve of the muffler – do not scrape it
along the muffler outer sleeve! (Figure 47, 48).
Figure 47
6.
Figure 48
Position the muffler with welded link-pipe correctly, slide it into the outlet side of the catalytic converter box outlet and
attach the spring (Figure 49, 50).
WARNING: be careful not to damage graphite gasket during this process!
WARNING: make sure, that spring pull the link pipe all the way into the outlet!
Figure 49
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Figure 50
11
7.
Attach and hand tighten the carbon-fiber clamp onto muffler bracket using bolt, nut and washer supplied in the Akrapovic
kit as shown in figures (Figure 51, 52). Align the muffler in respect to the motorcycle. Tighten the carbon-fiber clamp and
metal clamp of link pipe/collector joint (Figure 53, 54).
Figure 51
Figure 52
21Nm
15ftlb
21Nm
15ftlb
Figure 53
8.
Figure 54
For OPTIONAL LINK PIPE only: tighten the metal clamp of muffler link pipe joint (Figure 55). Make sure that link pipe or
muffler are not touching the swing arm or any other part of the motorcycle.
9,8Nm
7ftlb
Figure 55
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9.
For STREET LEGAL SLIP-ON only: reinstall the cables onto the Akrapovic exhaust valve in the reverse order from the
order in which they were removed (Figure 56, 57).
9.8Nm
7ftlb
Figure 56
Figure 57
10. For STREET LEGAL SLIP-ON only: adjust the cable adjusters to original position, tighten the nuts and slide the rubber
protection over adjusters (Figure 58, 59, 60).
9.8Nm
7ftlb
Figure 59
Figure 58
Figure 60
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11. For STREET LEGAL SLIP-ON only: Install the heat / distance washers correctly (Figure 61). Correctly position and
tighten the Akrapovic carbon-fiber heat shield valve protector onto the link pipe (Figure 62, 63).
Figure 62
Figure 61
9.8Nm
7ftlb
Figure 63
Final installation:
1. Clean grease spots:
a. Muffler – carbon-fiber outer sleeve: use a soft dry cloth.
b. Muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or
equivalent).
c. Muffler – carbon-fiber outlet cap: use a soft dry cloth.
d. Stainless steel inlet cap and welded link pipe: use a soft cloth sprayed with a contact cleaner, then wipe with a
soft dry cloth.
e. Titanium inlet cap and welded link pipe: 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: after running engine for 30 minutes, retighten the bolts on the Akrapovic carbon-fiber heat shield!
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2.
Check the operation of the brakes and suspension. 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.
!
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 AKRAPOVIC EXHAUST SYSTEMS.
MAINTENANCE OF THE AKRAPOVIC EXHAUST SYSTEM
1.
2.
3.
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. Do not use aggressive chemical cleaners, because they can damage the sticker. A change in the
color of the exhaust system is normal due to the high temperatures.
The wearing out of the muffler silencing material depends on the type of the engine and riding style. Contact your
dealer/serviceman if visible changes appear on muffler's outer sleeve or the noise level is increased.
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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