AKRAPOVIC E-D12E5 Ducati Scrambler 800 Optional Header Installation Guide
- October 27, 2023
- akrapovic
Table of Contents
- GENERAL INFORMATION
- SAFETY AND COMPLIANCE WARNING, PLEASE READ CAREFULLY
- NOISE AND EMISSION WARNINGS
- Tools & equipment
- PARTS LIST
- REMOVAL OF STOCK EXHAUST SYSTEM:
- INSTALLATION OF THE AKRAPOVIČ EXHAUST SYSTEM:
- FINAL INSTALLATION:
- MAINTENANCE OF THE AKRAPOVIČ PRODUCT:
- TROUBLESHOOTING
- References
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
E-D12E5 Ducati Scrambler 800 Optional Header
Installation Guidewww.akrapovic.com
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.
The shape of the Akrapovič product is protected under a registered Community
Design No. RCD 0090617240001.
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.
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 productrelated
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:
| TOOLS AND PROTECTIVE
EQUIPMENT REQUIRED
---|---
| LUBRICATION
| INSTALLATION TIP
| 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. Keep out of reach of children.
| USE ANTI-SEIZING GREASE (white tube)
Prevents seizing, corrosion and excessive wear between the titanium
components.
WARNING! Avoid eye contact. Keep out of reach of children.
| TIGHTENING TORQUE
| HAND TIGHTEN
| CAUTION OR IMPORTANT
Tools & equipment
- Mechanic gloves
- T-handle swivelling 10 mm wrench
- Combination 17 mm wrench
- Combination 22 mm wrench
- Torx 40 wrench
- Torx 45 wrench
- T-handle 4 mm hexagon wrench
- Spring puller
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.
-
Loosen the marked clamp and unscrew marked bracket bolt than carefully remove the muffler off the motorcycle (F 01).
IMPORTANT: be careful not to damage any part of the motorcycle during this procedure!
-
Unscrew the marked lambda sensor (F 02).
CAUTION: make sure not to damage the lambda sensor’s electrical lead during this process!
CAUTION: be careful not to damage any part of the motorcycle during this process!
-
Loosen the marked clamp and unscrew the flange nuts; carefully remove the header pipes off the motorcycle (F 03, 04).
CAUTION: be careful not to injure yourself or damage any part of the motorcycle during this procedure!
-
Unscrew the marked bolts and remove both parts of the heat shield off the header pipe (F 05, 06).
CAUTION: make sure not to damage any part of the heat shield during this process!
INSTALLATION OF THE AKRAPOVIČ EXHAUST SYSTEM:
-
Install the clamp from Akrapovič installation kit onto the link pipe’s inlet as shown (F 07).
CAUTION: be careful not to injure yourself or damage any part of the exhaust during this procedure!
-
Assemble the link pipe, header pipe and collector using springs from Akrapovič installation kit as shown (F 08).
CAUTION: make sure, that springs pull the collector all the way onto the headers – use rubber mallet if necessary to tap the connections into place!
INSTALLATION TIP: coat the interior side of the input bushes of the titanium collector with Akrapovič ceramic anti-seizing grease (white tube).
-
Install the reducing bush with gasket from Akrapovič installation kit into the lambda sensors bush and tighten it to the specified torque (F 09).
-
Install the assembled header onto the motorcycle and tighten the clamp and header flange nuts to the specified torques (F 10, 11).
INSTALLATION TIP: use new original exhaust port gasket.
CAUTION: be careful not to injure yourself or damage any part of the motorcycle during this procedure!
-
Tighten the lambda sensor into the header pipe to the specified torque (F 12).
CAUTION: make sure not to damage the lambda sensor’s electrical lead during this process!
CAUTION: be careful not to damage any part of the motorcycle during this process!
-
Reinstall the both parts of the stock heat shield, using stock bolts and tighten it to the specified torque (F 13, 14).
CAUTION: be careful not to damage any part of the motorcycle during this process!
CAUTION: use bolt sealant on marked bolt threads
-
Position the mufflers with link pipe correctly, slide it onto the optional header outlet and tighten the muffler’s bracket bolt and clamp to the specified torques (F 15, 16).
IMPORTANT: be careful not to damage the exhaust or any other part of the 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
Problem | Possible cause | Solution |
---|
Exhaust gas leaks out of the
muffler/pipe clamp connections| loosened clamp| tighten the clamp to specified
torque
connection is not completely joined| tap the connection into place and tighten
the clamp to specified torque
References
- Akrapovič | World Championship-Winning Exhaust System Technology
- Akrapovič | World Championship-Winning Exhaust System Technology