AKRAPOVIC Kawasaki Z650 Winning Exhaust System Installation Guide
- June 13, 2024
- akrapovic
Table of Contents
AKRAPOVIC Kawasaki Z650 Winning Exhaust System Installation Guide
Congratulations on purchasing the Akrapovič product. The Akrapovič product is made by Akrapovič d.d., Malo Hudo 8a, 1295 Ivančna Gorica, Slovenia (“Akrapovič”).
Please read this entire installation manual carefully prior to installing and using the Akrapovič product.
Akrapovič product should only be installed by persons skilled in motorcycle exhaust system or other motorcycle parts installation and performance. The instructions provided in this manual should be followed to ensure proper installation and safe use of the Akrapovič product. Akrapovič and/or its partners shall not be held liable for any damage or personal injury (including direct, indirect, or consequential damage) sustained as a result of improper installation of the Akrapovič product or its use and maintenance contrary to the instructions and warnings contained herein.
If you have any questions regarding the installation and/or proper use of the Akrapovič product or this manual, please contact your local Akrapovič partner.
For more information on the Akrapovič product, see the official Akrapovič
website at:
http://www.akrapovic.com
GENERAL INFORMATION
Your safety is our number one priority. Please ride your motorcycle
responsibly, safely and always obey local
traffic rules.
All statements made with regard to the product’s compliance are made in
respect of the product “as is”. Any
modifications of the Akrapovič product or its improper installation, use or
maintenance that is not in accordance with this Installation manual, may
result in severe damage to the product and/or motorcycle, as well as personal
injury, and may affect the product’s compliance with the legal requirements,
such as product’s air and/or noise emissions (as an example, the motorcycle
may not be suitable for use on public roads any longer), as well as warranty
coverage.
The product may only be used in accordance with relevant laws and regulations,
including state and federal,
where applicable.
Damage caused by improper installation, use and maintenance of the Akrapovič
product is not covered by the
Akrapovič warranty. Please refer to the enclosed warranty with regard to the
terms of our warranty.
Technical specifications of Akrapovič products are subject to change without notice.
COPYRIGHT AND OTHER RIGHTS NOTICE
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.
Any reproduction, technical or other manipulation, translation, or other use of the copyright and/or trademark rights contained herein is prohibited without the explicit prior written consent of Akrapovič. The same especially applies to the entire contents of this manual and/or any of its parts, including but not limited to technical specifications, instructions, graphs, photographs, and so on included in this manual.
Akrapovič takes all copyright and other rights infringement cases under
serious consideration. If you have any
reason to believe that your product is not an original Akrapovič product,
please contact our local partners or
Akrapovič at info@akrapovic.com.
SAFETY AND COMPLIANCE WARNING, PLEASE READ CAREFULLY
BEFORE REMOVING THE STOCK PARTS AND BEGINNING THE INSTALLATION OF YOUR NEW AKRAPOVIČ PRODUCT, PLEASE MAKE SURE THAT ALL ITEMS LISTED BELOW ARE VERIFIED:
- THIS MANUAL IS SPECIFIC TO THE MOTORCYCLE INDICATED ON THE COVER PAGE, FOR WHICH IT IS DESIGNED. INSTALLATION PROCEDURES VARY DEPENDING ON THE TYPE OF MOTORCYCLE. PLEASE VERIFY THAT THE AKRAPOVIČ PRODUCT AND THIS INSTALLATION MANUAL CORRESPOND TO THE TYPE OF YOUR MOTORCYCLE.
- FOR EXHAUST SYSTEM ONLY: THE EXHAUST SYSTEM CAN GET EXTREMELY HOT DURING AND AFTER IT IS USED. MAKE SURE NOT TO TOUCH THE EXHAUST SYSTEM UNTIL IT IS COMPLETELY COOL. ALLOW THE EXHAUST AND ENGINE TO COOL DOWN BEFORE BEGINNING INSTALLATION OR ANY OTHER WORK ON THE MOTORCYCLE.
- MAKE SURE THE MOTORCYCLE IS SECURELY POSITIONED TO PREVENT TIPPING OVER AND DAMAGE TO YOURSELF AND OTHERS, OR THE MOTORCYCLE.
- PLEASE CHECK THE PARTS YOU RECEIVED AGAINST THE PARTS LIST AVAILABLE ON OUR WEBSITE (PLEASE USE THE QR CODE ON THE FRONT PAGE OR LOOK FOR “SCHEMATIC VIEW” IN THE RESPECTIVE PRODUCT PAGE ON WWW.AKRAPOVIC.COM). MAKE SURE THAT YOU HAVE ALL THE PARTS NECESSARY FOR THE INSTALLATION OF YOUR NEW AKRAPOVIČ PRODUCT. IF ANY OF THE PARTS IS MISSING, PLEASE DO NOT PROCEED WITH UNINSTALLING YOUR STOCK PARTS/ INSTALLING THE AKRAPOVIČ PRODUCT AND CONTACT THE RETAILER WHERE YOU PURCHASED THE AKRAPOVIČ PRODUCT.
- ALWAYS CHECK YOUR MOTORCYCLE’S GROUND CLEARANCE. FOR ADVANCED USERS, WE RECOMMEND YOU CHECK THE MOTORCYCLE SPRING PRELOAD SETTINGS TO OPTIMIZE GROUND CLEARANCE WHERE POSSIBLE.
- FOR EXHAUST SYSTEM ONLY: EVERY EXHAUST SYSTEM MUFFLER HAS ITS UNIQUE SERIAL NUMBER, WHICH IDENTIFIES THE AUTHENTICITY OF THE PRODUCT. YOU CAN FIND THE SERIAL NUMBER ON THE MUFFLER’S INLET PIPE. PLEASE REFER TO THE PICTURE BELOW. PLEASE VERIFY THAT YOUR EXHAUST SYSTEM IS AN ORIGINAL AKRAPOVIČ PRODUCT. IF YOU HAVE ANY DOUBTS, PLEASE CONTACT THE RESELLER WHERE YOU PURCHASED THE EXHAUST SYSTEM OR AKRAPOVIČ PARTNERS. THIS MANUAL, ANY CERTIFICATES AND AKRAPOVIČ WARRANTY APPLY TO ORIGINAL PRODUCTS ONLY.
EXAMPLES OF SERIAL NUMBER POSITION
NOISE AND EMISSION WARNINGS
General warning
Because of the world-wide distribution of Akrapovič d.d. products, neither
Akrapovič d.d. nor any of its subsidiaries make any representation that the
products comply with the air and/or noise emissions laws, or labeling laws, of
any jurisdiction. The purchasers are entirely responsible for informing
themselves of the applicable laws where the products are to be used and to
comply with those law.
Although legal compliance of Akrapovič products in a specific country should
be determined by the user, you can find some basic guidance on compliance of
your Akrapovič product with various legal requirements on the product related
part of our website (please use the QR code on the front page or look for the
respective product page on www.akrapovic.com). For
EC and ECE type approvals, please refer to the certificate enclosed to your
product.
USA WARNING
Various U.S. states and the U.S. federal government have individual laws
regulating the use of aftermarket parts and systems, especially as those parts
and systems modify, remove, or replace original equipment catalysts. Please
consult the appropriate laws in your area before installing any aftermarket
part or system on your vehicle to ensure compliance with all applicable laws.
Neither Akrapovic d.d. nor any of their subsidiaries or the sellers of the
parts or systems make any representation that any of their parts or systems
comply with any such laws.
CALIFORNIA WARNING
California laws prohibit the use of any aftermarket part or system that modifies, removes or replaces original equipment catalysts unless the California Air Resources Board has issued an Executive Order regarding such part or system or unless the part or system is exempted by being used only on racing vehicles on closed courses. Neither Akrapovic d.d. nor any of their subsidiaries make any representation that any of their parts or systems has received such an Executive Order or that any of their parts or systems conform with the racing vehicles exemption. The purchasers are entirely responsible for informing themselves of applicable California laws and to comply with those laws.
GENERAL NOTE
Photographs and other illustrations in this manual are symbolic and are intended to help represent individual steps for proper installation and use, as well as for a general overview. The actual component parts of the Akrapovič product may not entirely correspond to the photographs and other illustrations.
SYMBOLS
The following symbols are used throughout these installation instructions:
PARTS LIST
The packaging box should contain one or more of the following items:
- Akrapovič product
- Homologation certificate/ compliance documents if applicable
- Warranty
- Fitting material
- Installation Manual
Detailed list of parts can be found on the Akrapovič website (please use the QR code on the front page or look for “Schematic view” in the respective product page on www.akrapovic.com).
REMOVAL OF STOCK EXHAUST SYSTEM OR OTHER STOCK MOTORCYCLE PARTS:
The process of uninstalling the original exhaust system or other motorcycle
parts, may vary depending on the existing exhaust system or other motorcycle
parts. Please follow the motorcycle manufacturer’s workshop manual for
uninstalling the original exhaust system or other motorcycle parts.
If you for any reason decide otherwise, please note that any information
provided in this respect herein should be considered as general information
provided for your convenience only. Akrapovič shall not assume any liability
or responsibility with regard to uninstalling your existing exhaust system or
other parts of the motorcycle, warranty coverage of such exhaust system or
other motorcycle parts vehicle or their further fitness for use.
In case your Akrapovič exhaust system or other motorcycle parts may not be
used on certain roads or under certain conditions, please keep the stock (or
other) exhaust system or other stock parts that you can use in such
circumstances legally.
REMOVAL OF STOCK EXHAUST SYSTEM:
- Put the motorcycle on a side stand, we recommend a central racing stand. Make sure, that surface is solid and flat.
- Unscrew marked bolt and partially remove the shift lever (F 01).
CAUTION: be careful not to injure yourself or damage any part of the motorcycle during this procedure!
3.Unscrew header’s flange nuts (F 02).
IMPORTANT: support the exhaust system during this process!
CAUTION: be careful not to injure yourself or damage any part of the
motorcycle during this procedure!
4. Unscrew the lambda sensors out off the exhaust (F 03).
IMPORTANT: make sure not to damage the lambdas sensor’s electrical lead
during this procedure!
Unscrew marked nut, pull out muffler’s bracket bolt, as shown and remove the
exhaust system off the motorcycle (F 04).
CAUTION: be careful not to injure yourself or damage any part of the
motorcycle during this procedure!
INSTALLATION OF THE AKRAPOVIČ EXHAUST SYSTEM:
1. Set up and hand tighten the flanges together with the springs and sleeves
onto the cylinder head, using stock nuts; make
sure you orient the flanges and springs, as shown (F 05).
IMPORTANT: do not fully tighten the flanges yet!
INSTALLATION TIP: use new stock exhaust port gaskets
2. Slide the collector onto the header tubes and attach the springs (F 06).
IMPORTANT: make sure, that springs pull the collector all the way onto the
headers – use rubber mallet if necessary to tap the connection into
place!
3. Insert the Akrapovič catalytic converter into the collector, as shown (F
07).
IMPORTANT: EC TYPE APPROVAL IS VALID ONLY IF CATALYTIC CONVERTER IS
INSTALLED!
4. Assemble the bracket onto the muffler and tighten it to the specified
torque, using bolts from Akrapovič installation kit (F 08).
IMPORTANT: use bolt sealant on all four bolt threads!
5. Slide the headers onto the muffler’s inlet, as shown and attach the springs from Akrapovič installation kit (F 09).
IMPORTANT: make sure, that springs pull the headers all the way onto the muffler – use rubber mallet if necessary to tap the connection into place!
6. Install the Akrapovič exhaust system onto the motorcycle; Insert the
headers into the sleeves and attach the springs (F 10).
IMPORTANT: make sure, that springs pull the headers all the way into the
sleeves – use rubber mallet if necessary to tap the connection into place!
IMPORTANT: support the exhaust system during this process!
IMPORTANT: be careful not to damage any part of the motorcycle during this
procedure!
7. Align the muffler in respect to the motorcycle and tighten the muffler’s
bracket onto the frame to the specified torque, using bolts and washers from
Akrapovič installation kit (F 11).
IMPORTANT: be careful not to damage any part of the motorcycle during this
process!
8. Tighten the header’s flanges to specified torque (F 12).
IMPORTANT: be careful not to damage the radiator or any other part of the
motorcycle during this process!
9. Tighten the lambda sensor into the collector to the specified torque (F
13).
IMPORTANT: be careful not to damage any part of the motorcycle during this
procedure!
IMPORTANT: make sure not to damage the lambda sensor’s electrical lead
during this process!
10. Unscrew marked bolts on both sides of the motorcycle and remove the
plastic fairings off the motorcycle (F 14, 15).
IMPORTANT: be careful not to damage any part of the motorcycle during this
procedure!
11. Reroute the lambda sensor’s electrical lead onto the other side of the
motorcycle, as shown. Secure the lambda’s sensor’s electric lead using tie
wraps from Akrapovič installation kit (F 16, 17, 18).
IMPORTANT: be careful not to damage any part of the motorcycle during this
procedure!
IMPORTANT: make sure not to damage the lambda sensor’s electrical lead
during this process!
12. Tighten the lambda sensor into the muffler, to the specified torque (F
19).
IMPORTANT: be careful not to damage any part of the motorcycle during this
procedure!
IMPORTANT: make sure not to damage the lambda sensor’s electrical lead
during this process!
13. Reinstall all dismounted stock parts in the reverse order from the order
in which they were removed. Check motorcycle manufacturer manual for correct
tightening torques.
IMPORTANT: make sure not to damage any part of the exhaust system or
motorcycle during this procedure!
FINAL INSTALLATION:
- Clean grease spots off all Akrapovič product’s surfaces, when installation is finished. Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can damage the surface or stickers:
• Titanium surfaces (titanium muffler’s outer sleeve, titanium pipes etc): use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40® or equivalent), then wipe with a soft dry cloth.
• Carbon-fiber surfaces (carbon-fiber outlet cap, carbon-fiber muffler’s outer sleeve, carbon-fiber bracket etc): use a soft dry cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
• Painted surfaces (painted outlet cap, painted muffler’s outer sleeve, painted bracket etc): use a soft
cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
• Chrome plated surfaces (chrome plated outlet cap, chrome plated muffler’s outer sleeve etc): use a soft cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
• Stainless steel surfaces (stainless steel muffler’s outer sleeve, stainless steel pipes etc): use a soft
cloth sprayed with a contact cleaner, then wipe with a soft dry cloth.
WD-40® is a trademark of the WD-40 Company. - Make sure all the nuts and bolts are sufficiently tightened. In case the Akrapovič product touches the cowling or other parts, repeat the adjustment of the product or contact your authorized dealer.
- Reinstall all dismounted or partially removed stock parts (cowlings, radiator etc); check vehicle manufacturer workshop manual for correct procedures and tightening torques.
MAINTENANCE OF THE AKRAPOVIČ PRODUCT:
IMPORTANT: periodically make sure all the bolts and springs are sufficiently
tightened. In case the product touches the cowling or other parts repeat the
adjustment of the product or contact your authorized dealer!
CAUTION: after running engine for 30 minutes, retighten the bolts of the
Akrapovič carbon-fiber heat shield!
IMPORTANT: IT IS NORMAL IF WHITE SMOKE COMES OUT OF THE MUFFLER DURING THE
FIRST 100 KM AFTER REPLACEMENT.
IMPORTANT: A CHANGE IN THE COLOR OF THE EXHAUST SYSTEM IS NORMAL DUE TO THE
HIGH TEMPERATURES.
CAUTION: DO NOT STAND BEHIND THE MUFFLER AT ANY TIME.
IMPORTANT: DO NOT USE AUTOMOTIVE WHEEL CLEANERS OR ANY CLEANING PRODUCTS WHICH
CONTAIN ACIDIC ADDITIVES TO CLEAN AKRAPOVIČ PRODUCTS.
IMPORTANT: WE RECOMMEND HIGH CAUTION WHEN USING POWER / PRESSURE WASHER FOR
CLEANING PAINTED / LACQUERED SURFACES OF THE AKRAPOVIČ PRODUCTS, TO AVOID
PAINT / LACQUER DAMAGE.
IMPORTANT: ALL AKRAPOVIČ PRODUCTS ARE DEVELOPED AND DESIGNED TO BE USED ON
SPECIFIC VEHICLES, FOR THEIR ENTIRE EXPECTED LIFETIME. PLEASE MAKE SURE THAT
END-OF-LIFE AKRAPOVIČ PRODUCT IS DISASSEMBLED TO COMPONENTS SHOWN IN THE
PRODUCT’S SCHEMATIC DIAGRAM AVAILABLE ON THE AKRAPOVIČ WEBSITE AND EACH
COMPONENT SCRAPPED RESPONSIBLY AND ACCORDING TO APPLICABLE LOCAL LAWS AND
REGULATIONS. AKRAPOVIČ DOES NOT ASSUME ANY OBLIGATION OR RESPONSIBILITY WITH
RESPECT TO THE SCRAPPING PROCESS OR PROVIDING INFORMATION RELATED THERETO.
TROUBLESHOOTING:
References
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