AKRAPOVIC Exhaust System Slip-On Line for Aprilia RSV4, Aprilia TUONO V4 Installation Guide

AKRAPOVIC Exhaust System Slip-On Line for Aprilia RSV4, Aprilia TUONO V4

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 exhaust system’s compliance are made in respect of the exhaust system “as is”. Any modifications of the Akrapovic exhaust system or its improper installation, use or maintenance that is not in accordance with this Installation manual, may result in severe damage to the exhaust system and/ or engine, as well as personal injury, and may affect the exhaust system’s compliance with the legal requirements, such as exhaust system’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 exhaust system 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 Akrapovic exhaust system 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 exhaust systems and related products are subject to change without notice.

SAFETY AND COMPLIANCE WARNING, PLEASE READ CAREFULLY

BEFORE REMOVING THE STOCK EXHAUST SYSTEM AND BEGINNING THE INSTALLATION OF YOUR NEW AKRAPOVIČ EXHAUST, 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 EXHAUST SYSTEM AND THIS INSTALLATION MANUAL CORRESPOND TO THE TYPE OF YOUR MOTORCYCLE.
• 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 EXHAUST SYSTEM.
• 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 EXHAUST SYSTEM. IF ANY OF THE PARTS IS MISSING, PLEASE DO NOT PROCEED WITH UNINSTALLING YOUR STOCK EXHAUST SYSTEM/ INSTALLING THE AKRAPOVIČ EXHAUST SYSTEM AND CONTACT THE RETAILER WHERE YOU PURCHASED THE AKRAPOVIČ EXHAUST SYSTEM.
• ALWAYS SECURE YOUR MOTORCYCLE’S GROUND CLEARANCE. FOR ADVANCED USERS, WE RECOMMEND YOU CHECK THE MOTORCYCLE SPRING PRELOAD SETTINGS TO OPTIMIZE GROUND CLEARANCE WHERE POSSIBLE.
• 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.

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 exhaust system 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 exhaust 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 exhaust 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 exhaust system may not entirely correspond to the photographs and other illustrations.

SYMBOLS
The following symbols are used throughout these installation instructions:

Tools & equipment

• Mechanic gloves
• T-handle 3 mm hexagon wrench
• T-handle 4 mm hexagon wrench
• T-handle 6 mm hexagon wrench
• T- handle swiveling 2.5 mm hexagon wrench
• T- handle swiveling 3 mm hexagon wrench
• Combination 8 mm wrench
• Combination 10 mm wrench
• T- handle swiveling 13 mm wrench
• Crosshead screwdriver
• Spring puller

PARTS LIST

The following parts should be found in the box:

• Installation Manual
• Homologation certificate/ compliance documents if applicable
• Warranty
• Fitting material
• Muffler and pipes

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:
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. 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, warranty coverage of such exhaust system or vehicle or their further fitness for use. In case your Akrapovič exhaust system may not be used on certain roads or under certain conditions, please keep the stock or other exhaust system that you can use in such circumstances legally.

REMOVAL OF STOCK EXHAUST SYSTEM:

1. Put the motorcycle on a side stand, we recommend a central racing stand. Make sure, that surface is solid and flat.

2. For Aprilia Tuono V4 only: unscrew the marked bolts, undo the plastic fastener and carefully remove the right side cowling of the motorcycle (F 01, 02).
   CAUTION: be careful not to injure yourself or damage any part of the motorcycle during this procedure!

3. For Aprilia RSV4 only: unscrew marked bolts on both sides of the motorcycle than carefully remove the belly pan of the motorcycle (F 03).
   CAUTION : be careful not to injure yourself or damage any part of the motorcycle during this procedure!

4. For Aprilia RSV4 only: unscrew marked bolts and carefully remove the right side cowling of the motorcycle (F 04, 05, 06, 07, 08).
   CAUTION : be careful not to injure yourself or damage any part of the motorcycle during this procedure!

5. Unscrew marked bolt and loosen marked clamp (F 09, 10).
   IMPORTANT: be careful not to damage any part of the motorcycle during this procedure!

6. Partially remove stock muffler, loosen marked nuts and carefully remove valve cables off the bracket and muffler. Carefully remove stock muffler off the motorcycle (F 11).
   CAUTION: be careful not to injure yourself or damage any part of the motorcycle during this procedure!

7. Unscrew marked bolts and partially remove valve actuator than disconnect electrical valve connectors from actuator. (F 12, 13, 14).
   IMPORTANT: be careful not to damage any part of the motorcycle during this procedure!

8. Unscrew marked nuts remove the plastic bracket of the actuator than disconnect and carefully remove the exhaust valve cables off the actuator and from the motorcycle (F 15, 16).
   IMPORTANT: be careful not to damage any part of the motorcycle during this procedure!

9. Assemble and reinstall the valve actuator, without cables, onto the motorcycle in reverse order as it was removed. Check vehicle workshop manual for tightening torques (F 17).
   IMPORTANT: be careful not to damage any part of the motorcycle during this procedure!

INSTALLATION OF THE AKRAPOVIČ EXHAUST SYSTEM:

1. For Aprilia Tuono V4 only: use and correctly install the bigger spring hook clamp (Akrapovic installation kit) onto  the stock collector as shown and tighten it to the specified torque. Notice the marked engravings for determining the correct position (F 18).
   CAUTION : be careful not to injure yourself or damage any part of the motorcycle during this procedure!

2. For Aprilia RSV4 only: correctly install the smaller spring hook clamp (Akrapovic installation kit) onto the stock collector as shown and tighten it to the specified torque (F 19).
   CAUTION : be careful not to injure yourself or damage any part of the motorcycle during this procedure!

3. Install the clamp onto the link pipe’s inlet as shown (F 20).
   IMPORTANT : hand tighten the clamp only!

4. Slide the link pipe onto the stock collector, attach the spring and hand tighten the clamp (F 21, 22, 23).
   IMPORTANT : 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!!

5. Correctly position the carbon-fiber clamp (check the position of the yellow sticker) and carefully slide it onto the muffler (F 24).
   IMPORTANT : open the carbon-fiber clamp slightly wider than the diameter of the outer sleeve of the muffler do not scrape it along the muffler outer sleeve!

6. For Aprilia Tuono V4 only: position the muffler correctly, slide it onto the outlet of the Link pipe, attach the springs and hand tighten it using stock bolt, washer and threaded bush (F 25).
   CAUTION : be careful not to injure yourself or damage any part of the motorcycle during this procedure!
   INSTALLATION TIP : coat the interior side of the inlet bush of the muffler with Akrapovič ceramic antiseizing grease (white tube).

7. For Aprilia RV4 only: position the muffler correctly, slide it onto the outlet of the Link pipe attach the springs and hand tighten it using stock bush, bolt, spacer bush, washer and nut from Akrapovic installation kit (F 26).
   CAUTION: be careful not to injure yourself or damage any part of the motorcycle during this procedure!
   INSTALLATION TIP : coat the interior side of the inlet bush of the muffler with Akrapovič ceramic antiseizing grease (white tube).

8. Align the muffler and Link pipe in respect to the motorcycle. Tighten the muffler’s carbon-fiber clamp onto the bracket to the specified torque (F 27, 28).
   CAUTION: be careful not to damage any part of the motorcycle or exhaust system during this process!

9. Tighten the clamp to the specified torque (F 29).
   CAUTION: be careful not to damage any part of the motorcycle or exhaust system during this process!

10. Replace all dismounted stock parts in the reverse order from the order in which they were removed. Check motorcycle workshop manual for correct tightening torques.
    IMPORTANT: be careful not to damage any part of the motorcycle during this procedure!

FINAL INSTALLATION AND MAINTENANCE:
Clean grease spots off all exhaust system 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 sticker.

1. Muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent)*.
2. Muffler – carbon-fiber outer sleeve: use a soft dry cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
3. Muffler – carbon-fiber outlet cap: use a soft dry cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
4. Painted mufflers and parts – use a soft cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
5. Chrome plated mufflers and parts: use a soft cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
6. Stainless steel pipes: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth.
7. Titanium pipes: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 WD-40 or equivalent).  ® is a trademark of the WD-40 Company.

Periodically make sure all the bolts and springs are sufficiently tight.

• IMPORTANT: 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!
• CAUTION : after running engine for 30 minutes, retighten the bolts of the Akrapovič carbon-fiber heat shield!
• INSTALLATION TIP: IT IS NORMAL IF WHITE SMOKE COMES OUT OF THE MUFFLER DURING THE FIRST 100 KM AFTER REPLACEMENT.
• INSTALLATION TIP: 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 EXHAUST SYSTEMS.
• IMPORTANT: WE RECOMMEND HIGH CAUTION WHEN USING POWER / PRESSURE WASHER FOR CLEANING PAINTED / LACQUERED SURFACES OF THE AKRAPOVIČ COMPONENTS, 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:

**

www.akrapovic.com

References

• Akrapovič | World Championship-Winning Exhaust System Technology

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