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Installation instructions

Akrapovič Exhaust SystemSlip-Onfor theAprilia RSV4 Aprilia Tuono V4

*502250*

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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 Liability1. Themanufacturer,importerordealershallnotbeliableforanyincidentaldamageincludingpersonalinjury

oranyotherdamagescausedbyimproperinstallationoroperationoftheAkrapovičexhaustsystem.Wheninstalling theAkrapovič exhaust systembe careful that the exhaust systemdoes not touch other partssensitivetohightemperature.

2. Akrapovičmakesnorepresentationorwarrantieswithregardtodamagecausedbytheimproperinstallation,useandmaintenanceoftheAkrapovičexhaustsystem.Thewarrantyislimitedtodefectsrecognizedbyourtechnicaldepartmentandduetonormaluse,andexcludesitemssubjecttonormalwear(gasketsanddampingwool).Theguaranteeisvoidincaseofaccident,modification,improperorcompetitionuse.

3. Donotattempttoinstall theAkrapovičexhaustsystemonavehiclemodelforwhichitwasnotmadeortestedbyAkrapovič.

4. Whentheexhaustsystemgetsveryhotduringoperation,becarefulnottoburnyourselfontheexhaustsystemorpartswhichareindirectcontactwithit,evenwhentheengineisnotrunning.Alsoprotectotherpeople,especiallychildren,fromtheinjuriesmentionedabove.

5. InsomecasesAkrapovičexhaustsystemkitscontainchemicalproducts(ceramicanti-seizinggrease;boltsealant).Handlewithcare,donot inhaleorswallow.Avoidexcessivecontactwithskin,eyesormucousmembranes.Keepoutofreachofchildren.

6. TechnicalspecificationsofAkrapovičexhaustsystemsandrelatedproductsaresubjecttochangewithoutnotice.

7. Before removing theoriginalexhaustsystemfromyourvehicle,pleasecompare thepartsyoureceivedwiththelistofmaterialsprovidedintheinstallationmanualinordertoassurethatyouhaveallthepartsnecessaryfortheinstallationofyournewAkrapovičexhaustsystem.

8. Although thismanualconsistsof instructions for installation inwritten form,aswellasphotographsandpictures representing individual stepsof the installation, pleasenote that thephotographsandpicturesaresymbolicandareintendedforrepresentationofgeneraloverviewonly.Thephotographsandpicturescontainedhereinshouldserveasaguidelineonlyandactual installationoftheexhaustsystemmaynotcorrespondwiththephotographsandpicturesentirely.

9. Theprocessofuninstallingtheoriginalexhaustsystemmayvarydependingontheexistingexhaustsystem.Pleasefollowtheoriginalexhaustsystemmanufacturer’sinstructionsforuninstallingtheoriginalexhaustsystem.

TrademarksTheAkrapovičExhaustSystemTechnologylogoisaregisteredtrademarkofAkrapovičd.d.

Akrapovič websiteInformationaboutAkrapovičexhaustsystemsandrelatedproductsisavailableontheAkrapovičwebsiteat:http://www.akrapovic.com/

CopyrightNopartoftheAkrapovičexhaustsystemoritsdocumentationmaybereproducedordistributedinanyformorbyanymeanswithoutthepriorwrittenauthorizationoftheAkrapovičcompany.

©Akrapovič,d.d.Allrightsreserved.

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T-handle 10 mm wrenchT-handle 3 mm three hexagon key wrenchT-handle 4 mm three hexagon key wrenchT-handle 5 mm three hexagon key wrenchT-handle 6 mm three hexagon wrenchCombination 13 mm wrenchSpring puller

CAUTIONORWARNINGINSTALLATION TIP

TOOLS REQUIRED TIGHTENING TORQUE

SymbolsThefollowingsymbolsareusedthroughouttheseinstallationinstructions:

USE BOLT SEALANT;Apply3to4smalldropsofboltsealantontothecleanedanddegreasedthreadsbeforetighteningthebolts.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(blacktube);Providestrouble-freeandlong-lastingprotectionagainstseizing,corrosionandrustingofbolts,threadedends,nuts,joints,etc.Alsoprotectsagainstvibration,wearandimpact. WARNING! Avoid eye contact. Avoid excessive skin contact. Keep out of reach of children.

USE ANTI-SEIZING GREASE(whitetube);Preventsseizing,corrosionandexcessivewearbetweenthetitaniumcomponentsofyourexhaustsystem.WARNING! Avoid eye contact. Avoid excessive skin contact. Keep out of reach of children.

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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Figure 1

Figure 2

Putthemotorcycleonasidestand,werecommendaracingstand.Unscrewthemarkedboltsfromthemufflerhanging,themetalclampatthemufflerlinkpipe-collectorconnectionandlowermufflerbracket(Figure 1, 2). Removethemuffler.

REMOVAL OF ORIGINAL EXHAUST SYSTEM:1.2.

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Figure 3

Figure 4

Removethemetalcollarandrubberdamperfromthestockmufflerhangingbracket(Figure 3, 4).3.

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Unscrewthemarkedboltsandremovetheplasticfastenersfromtheleftandrightsideofthecowling(Figure 5, 6).4.

Figure 5

Figure 6

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Unscrewthemarkedboltsandremovethelowerpartofthecowling (Figure 7).5.

Figure 7

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Figure 8

Figure 9

CoattheboltandinteriorofthemetalclampwithspringhookwhitAkrapovičanti-seizelead-freecopperpaste(blacktube)andcorrectlyinstallitontothestockcollector.Handtightenthebolt(Figure 9, 10). WARNING: use anti-seize copper paste on bolt threads and interior of the metal clamp!

2.

1. CoattheboltandinteriorofthemetalclampwithAkrapovičantiseizelead-freecopperpaste(blacktube)andcorrectlyinstallitontothelinkpipe(Figure 8).WARNING: use anti-seize copper paste on bolt threads and interior of the metal clamp!

INSTALLATION OF THE AKRAPOVIČ SLIP-ON EXHAUST SYSTEM:

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Figure 10

Figure 11

Slidethelinkpipeontothestockcollectorandattachthespring(Figure 11).WARNING: make sure, that spring pull the link pipe all the way onto the stock collector – use rubber mallet if necessary to tap the connection into place!

3.

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22Nm16ftlb

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Figure 12

Figure 13

Unscrewthemarkedboltsandremovethepassenger’sfootrest(Figure 12).

AttachtheadditionalAkrapovičstainlesssteelbrackettothestockpassenger’sfootrest,useingAkrapovičM8x16bolt(Figure 13).WARNING: use bolt sealent on M8x16 bolt threads!

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5.

22Nm16ftlb

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Figure 14

Figure 15

7. Attachasembledpassenger’sfootresttothesubframe,usingstockboltsorincaseofoptionalcarbonfiberbracketuseAkrapovičbolts(Figure 15).

For optional carbon fiber muffler bracket: asemblepassenger’sfootrestwiththeAkrapovičcarbonfibermufflerbracketusingAkrapovičbolts,washersanddistancebushes(Figure 14).

6.

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Figure 16

Figure 17

Correctlypositionthecarbon-fiberclampandslideitontothemuffler-bearinmindtheleft offsetofthecarbonfiber-clampviewedfromtherear(Figure 16, 17).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!

8.

22Nm16ftlb

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Figure 18

Figure 19

Positionthemufflercorrectlyandslideitontotheoutletsideofthelinkpipe.Attachthesprings(Figure 18). WARNING: make sure, that springs pull the muffler all the way onto the link pipe – use rubber mallet if necessary to tap the connection into place!INSTALLATION TIP: coat the interior of the muffler inlet bush with ceramic grease (white tube).

9.

AlignthemufflerinrespecttothemotorcycleandtightenthemufflerclampusingAkrapovičbolt,washerandalu-miniumdistancebushwithstockspacerbushandnutasshowninfigure(Figure 19, 20). INSTALLATION TIP: place the aluminium distance bush so, that the larger radius is on the muffler bracket.

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9.8Nm7ftlb

2Nm1.4ftlb

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Figure 20

Figure 21

Tightenthemetalclampandmetalclampwithspringhook(Figure 21).11.

2Nm1.4ftlb

2Nm1.4ftlb

1.5Nm1.05ftlb

1.5Nm1.05ftlb

1Nm0.7ftlb

1Nm0.7ftlb

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Figure 22

Figure 23

Attachthecowlingsinthereverseorderfromtheorderinwhichtheywereremoved(Figure 22, 23).WARNING: because of the risk of melting or fire, the drain pipes must be correctly attached to the cowling (Figure 23)! Make sure, that drain pipes doesn’t touch the exhaust pipe!

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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.

1. Cleanthetitaniumexhaustcomponentswithamulti-purposespraylubricant(WD-40orequivalent),carbonfiberexhaustcomponentswithsoftanddryclothandstainlesssteelcomponentswithsoftclothsprayedwithcontactcleaner,thenwipewithsoftanddrycloth.Achangeinthecoloroftheexhaustsystemisnormalduetothehightemperatures.

2. Periodicallymakesurealltheboltsandspringsaresufficientlytight.

WARNING: make sure all the bolts are sufficiently tightened. In case the exhaust system touches thecowling or other parts repeat the adjustment of the exhaust system or contact your authorized dealer.

Cleangreasespots:a. Muffler–carbon-fiberoutersleeve:useasoftdrycloth.b. Muffler–titaniumoutersleeve:useasoftclothsprayedwithamulti-purposespraylubricant(WD-40or

equivalent).c. Muffler–carbon-fiberoutletcap:useasoftdrycloth.d. Slip-Onwithstainlesssteellinkpipe:useasoftclothsprayedwithacontactcleaner,thenwipewita

softdryclothe. Slip-Onwithtitaniumllinkpipe:useasoftclothsprayedwithamulti-purposespraylubricant(WD-40or

equivalent).

Cleaningwillpreventspotsfromburningontothesurface.Donotuseaggressivechemicalcleaners,becausetheycandamagethesticker.

MAINTENANCE OF THE AKRAPOVIČ EXHAUST SYSTEM:

Final installation:

WARNING: check vehicle manufacturer manual for tightening torques (for dismounted stock parts)!

P-MBA10R6 CARBON FIBER MUFFLER BRACKET

APRILIA RSV4 SLIP ON exhaust system / OpenAPRILIA TUONO V4 Product code: S-A10SO6-ZT S-A10SO6-ZC

(P-HF) COLLECTOR FITTING KIT

P-HF360 FITTING KIT

P-HF400 CARBON MUFFLER BRACKET FITTING SET EVO2

P-MBA10R6/A2 CARBON MUFFLER BRACKET WITH FITTING SET EVO2 - OPTIONAL

P-HF401 MUFFLER SS BRACKET FITTING KIT

P-MBA10AL3/A2 ALU BRACKET WITH FITTING SET EVO2 - OPTIONAL

L-A10SO6T LINK PIPE

P-VST2AL STICKER

P-MCTZ4 CARBON FIBER CLAMP FOR TITANIUM OUTER SLEEVE MUFFLER P-MCCZ4 CARBON FIBER CLAMP FOR CARBON FIBER OUTER SLEEVE MUFFLER

P-S1 SPRING

M-Z01805T/5 TITANIUM OUTER SLEEVE MUFFLERM-Z01805C/5 CARBON FIBER OUTER SLEEVE MUFFLER

V-TUV049 NOISE REDUCTION INSERT

V-EC27 END CAP SET FOR TITANIUM OUTER SLEEVE MUFFLER V-EC26 END CAP SET FOR CARBON FIBER OUTER SLEEVE MUFFLER

P-R43D SS CLAMP WITH BRACKET

P-R44 SS CLAMP

P-TT18 BELT FOR TITANIUM OUTER SLEEVE MUFFLERP-TT19 BELT FOR CARBON FIBER OUTER SLEEVE MUFFER

P-TT18 BELT FOR TITANIUM OUTER SLEEVE MUFFLERP-TT19 BELT FOR CARBON FIBER OUTER SLEEVE MUFFER

3:10P-MBA10AL3 ALU MUFFLER BRACKET

MUFFLER REPAIR KITS

KIT Part Nr.

REPACK P-RPCK26

Ca SLEEVE P-RKS251ZC35

Ti SLEEVE P-RKS252ZT35

P-MBA10R6 CARBON MUFFLER BRACKET

APRILIA RSV4 SLIP-ON exhaust system / STREET LEGALAPRILIA TUONO V4 Product code: S-A10SO6C-HZT S-A10SO6C-HZC

P-HF COLLECTOR FITTING KIT

P-HF360 MUFFLER FITTING SET

P-HF400 CARBON MUFFLER BRACKET FITTING SET EVO2

P-MBA10R6/A2 CARBON MUFFLER BRACKET WITH FITTING SET EVO2 - OPTIONAL

P-HF401 MUFFLER SS BRACKET FITTING SET

P-MBA10AL3/A2 ALU MUFFLER BRACKET WITH FITTING SET - OPTIONAL

L-A10SO6CT TITANIUM LINK PIPE

P-VST2AL STICKER

P-MCTZ4 CARBON FIBER CLAMP FOR TITANIUM OUTER SLEEVE MUFFLER P-MCCZ4 CARBON FIBER CLAMP FOR CARBON FIBER OUTER SLEEVE MUFFLER

P-S1 SPRING

M-HZ00505T/2 TITANIUM OUTER SLEEVE MUFFLER M-HZ00505C/2 CARBON FIBER OUTER SLEEVE MUFFLER

V-TUV049/1 NOISE REDUCTION INSERT

V-EC27 END CAP SET FOR TITANIUM OUTER SLEEVE MUFFLER V-EC26 END CAP SET FOR CARBON FIBER OUTER SLEEVE MUFFLER

P-R43D SS CLAMP WITH BRACKET

P-R44 SS CLAMP

P-TT18 BELT FOR TITANIUM OUTER SLEEVE MUFFLERP-TT19 BELT FOR CARBON FIBER OUTHER SLEEVE MUFFLER

P-TT18 BELT FOR TITANIUM OUTER SLEEVE MUFFLERP-TT19 BELT FOR CARBON FIBER OUTHER SLEEVE MUFFLER

3:10

P-MBA10AL3 ALU MUFFLER BRACKET

MUFFLER REPAIR KITS

KIT Part Nr.

REPACK P-RPCK26

Ca SLEEVE P-RKS251ZC35

Ti SLEEVE P-RKS252ZT35

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APRILLIA RSV4/ Complete exhaust system/ RAC2 TUBE SET WITH SO-HOM MUFFLERAPRILIA TUONO V4, Complete exhaust system/ RAC2 TUBE SET WITH SO-HOM MUFFLERProduct code: S-A10R1-ZT/1 S-A10R1-ZC/1

(P-HF360) MUFFLER FITTING SET

(P-HF400) MUFFLER BRACKET FITTING SET EVO2

(P-MBA10R6/A2) MUFFLER BRACKET WITH FITTING SET EVO2

() STRIPES

(P-MBA10AL3/A2) ALU MUFFLER BRACKETWITH FITTING SET - OPTIONAL

0,200

(L-A10R2) LINK PIPE(P-VST2AL) STICKER

(P-MCTZ4) CARBON FIBER CLAMP FOR TI OUTER SLEEVE MUFFLER(P-MCCZ4) CARBON FIBER CLAMP FOR CA FIBER OUTER SLEEVE MUFFLER

(P-S1) SPRING

(M-HZ00505T/2) TITANIUM OUTER SLEEVE MUFFLER(M-HZ00505C/2) CARBON OUTER SLEEVE MUFFLER

(V-TUV049/1)NOISE REDUCTION INSERT (H-A10R1) HEADER TUBE SET

(P-FY4) FLANGE

(P-85) OUTER SLEEVE

(V-EC27) END CAP SET FOR TITANIUM OUTER SLEEVE MUFFLER

(V-EC26) END CAP SET FOR CARBON FIBER OUTER SLEEVE MUFFLER

(C-A10R1L) COLLECTOR

(P-MBA10R6) CARBON MUFFLER BRACKET

(P-TT18) BELT

0,250

COPPER PASTE

0,250

CERAMIC PASTE

(P-MBA10AL3) ALU MUFFLER BRACKET

WARNING! IN CASE OF COMBINATION WITH RAC2 TUBE SET, THE SLIP-ON HOMOLOGATION IS NOT VALID!

MUFFLER REPAIR KITS

REPACK P-RPCK26

SLEEVEP-RKS89ZT35 - TITANIUM

P-RKS88ZC35 - CARBON

(P-HF) COLLECTOR FITTING KIT

APRILLIA RSV4/ Complete exhaust system/ EVO2 TUBE SET WITH SO-HOM MUFFLERAPRILIA TUONO V4Product code: S-A10RFT1-ZT/1 S-A10RFT1-ZC/1

(P-HF360) MUFFLER FITTING SET

(P-HF400) MUFFLER BRACKET FITTING SET EVO2

(P-MBA10R6/A2) MUFFLER BRACKET WITH FITTING SET EVO2

() STRIPES

(P-MBA10AL3/A2) ALU MUFFLER BRACKETWITH FITTING SET - OPTIONAL

0,200

(L-A10E9T) LINK PIPE(P-VST2AL) STICKER

(P-MCTZ4) CARBON FIBER CLAMP FOR TI OUTER SLEEVE MUFFLER(P-MCCZ4) CARBON FIBER CLAMP FOR CA OUTER SLEEVE MUFFLER

(P-S1) SPRING

(M-HZ00505T/2) TITANIUM OUTER SLEEVE MUFFLER(M-HZ00505C/2) CARBON OUTER SLEEVE MUFFLER

(V-TUV049/1)NOISE REDUCTION INSERT (H-A10E3T) HEADER TUBE SET

(P-FY4) FLANGE

(P-85) OUTER SLEEVE

(V-EC27) END CAP SET FOR TITANIUM OUTER SLEEVE MUFFLER (V-EC26) END CAP SET FOR CARBON FIBER OUTER SLEEVE MUFFLER

(C-A10E1T) COLLECTOR

(P-MBA10R6) CARBON MUFFLER BRACKET

(P-TT18) BELT

0,250

COPPER PASTE

0,250

CERAMIC PASTE

(P-MBA10AL3) ALU MUFFLER BRACKET

WARNING! IN CASE OF COMBINATION WITH EVO2 TUBE SET, THE SLIP-ON HOMOLOGATION IS NOT VALID!

MUFFLER REPAIR KITS

REPACK P-RPCK26

SLEEVEP-RKS89ZT35 - TITANIUM

P-RKS88ZC35 - CARBON

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