Yamaha | YZF-R125 | Installation instructions

Installation instructions
Akrapovič Exhaust System:
Racing
for the
YAMAHA YZF-R125 2008-2010
*502642*
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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 Exhaust System Technology logo is a registered trademark of Akrapovič d.d.
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.
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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 12 mm wrench
T-handle 13 mm wrench
T-handle 4 mm three hexagon key wrench
T-handle 5 mm three hexagon key wrench
T-handle 6 mm three hexagon key wrench
Screwdriver - cross head
Spring puller
BEFORE INSTALLING, CHECK SCHEMATIC OF THE EXHAUST SYSTEM!
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.
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REMOVAL OF STOCK EXHAUST SYSTEM:
1. Put the motorcycle on a side stand, we recommend a racing stand.
2. Unscrew the marked bolts and remove the right upper part of the cowling (Figure 1).
Figure 1
3.
Unscrew the marked bolts and remove the right lower part of the cowling (Figure 2).
Figure 2
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4.
Unscrew the two marked nuts, undo the marked clamp and pull the emission tube of the stock header pipe (Figure 3).
Figure 3
5.
Unscrew the marked muffler braket bolts and remove the stock exhaust system off the motorcycle (Figure 4).
Figure 4
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6.
Unscrew the two marked footrest bolts (Figure 5).
Figure 5
INSTALLATION OF THE AKRAPOVIČ EXHAUST SYSTEM:
1.
Attach the Akrapovič distance bushes under the footrest as shown. Tighten the footrest bolts to a specified torque
(Figure 6).
22 Nm
16 ftlb
Figure 6
6
2.
Set up the sleeve together with the flange and springs, as shown (Figure 7).
Figure 7
3.
Install the assembled sleeve, flange and springs onto the motorcycle and hand tighten the two marked stock nuts (Figure 8).
WARNING: do not fully tighten the nuts yet!
INSTALLATION TIP: use new stock exhaust port gasket.
Figure 8
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4.
Insert the header tube into the sleeve, attach the springs and tighten the nuts to a specified torque. Re-do the
emission tube onto the Akrapovič header pipe, using stock clamp (Figure 9).
WARNING: before tightening the nuts, make sure, that springs pull the header tube all the way into the sleeve – use
rubber mallet if necessary to tap the connection into place!
22 Nm
16 ftlb
Figure 9
5.
Slide the link pipe onto the header tube and attach the spring. Tighten the market stock link pipe braket bolt to a
specified torque (Figure 10).
WARNING: before tightening the bolt, make sure, that springs pull the link pipe tube all the way onto the header – use
rubber mallet if necessary to tap the connection into place!
22Nm
16ftlb
Figure 10
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6.
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 rear (Figure 11, 12).
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 11
Figure 12
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7.
Position the muffler correctly and slide it onto the outlet side of the link pipe and attach the spring. Align the muffler in
respect to the motorcycle and tighten the muffler clamp using Akrapovič bolt and washer (Figure 13).
WARNING: make sure, that spring pull the muffler all the way onto the link pipe – use rubber mallet if necessary to tap the connection into place!
22 Nm
16 ftlb
Figure 13
8.
Reattach the stock right lower and upper parts of the cowling and tighten the marked stock bolts to a specified
torques (Figure 14).
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. RACING - stainless steel muffler link pipe and header tube: use a soft cloth sprayed with a contact
cleaner, then wipe with a soft dry cloth
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: check vehicle manufacturer manual for tightening torques (for dismounted stock parts)!
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.
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YAMAHA YZF-R125/ Complete exhaust system/ Racing line/ OPEN / model year: 2008-2010
Product code: S-Y125R1-ZC
S-Y125R1-ZT
P-F34 FLANGE
P-89 INNER SLEEVE
V-TUV110 NOISE REDUCTION INSERT
V-EC134 END CAP SET FOR CARBON FIBER OUTER SLEEVE
V-EC133 END CAP SET FOR TITANIUM OUTER SLEEVE
P-S2 SPRING
M-Z04302C MUFFLER WITH CARBON FIBER OUTER SLEEVE
M-Z04302T MUFFLER WITH TITANIUM OUTER SLEEVE
P-HF492 FITTING KIT
H-Y125R1 HEADER TUBE
P-VST2AL STICKER
L-Y125R1 LINK PIPE
P-MCCZ11 CARBON FIBER CLAMP FOR CARBON FIBER OUTER SLEEVE
P-MCTZ11 CARBON FIBER CLAMP FOR TITANIUM OUTER SLEEVE
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