General Information
Congratulations on purchasing the Akrapovič exhaust system. The Akrapovič exhaust system is a product of 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 exhaust system.
Akrapovič exhaust system should only be installed by persons skilled in motorcycle exhaust system installation and performance. The instructions provided in this manual should be followed to ensure proper installation and safe use of the Akrapovič exhaust system. 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 exhaust system or its use and maintenance contrary to the instructions and warnings contained herein.
If there are any questions regarding the installation and/or proper use of the Akrapovič exhaust system or this manual, please contact a local Akrapovič partner.
For more information on the Akrapovič exhaust systems, refer to the official Akrapovič website at: http://www.akrapovic.com
General Safety Information
Safety is the number one priority. Ride the 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 Akrapovič 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 Akrapovič exhaust system is not covered by the Akrapovič warranty. Refer to the enclosed warranty with regard to the terms of the warranty.
Technical specifications of Akrapovič exhaust systems and related 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 exhaust system is protected under a registered Community Design No. RCD 002747329-0001.
Akrapovič takes all copyright and other rights infringement cases under serious consideration. If there is any reason to believe that an exhaust system is not an original Akrapovič product, please contact local partners or Akrapovič at info@akrapovic.com.
Safety and Compliance Warning, Please Read Carefully
Before removing the stock exhaust system and beginning the installation of a 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 the 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 received against the parts list available on the Akrapovič website (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 all parts necessary for the installation of the new Akrapovič exhaust system are present. If any parts are missing, do not proceed with uninstalling the stock exhaust system/installing the Akrapovič exhaust system and contact the retailer where the Akrapovič exhaust system was purchased.
- Always secure the motorcycle's ground clearance. For advanced users, Akrapovič recommends checking 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. The serial number can be found on the muffler's inlet pipe. Refer to the picture below. Please verify that the exhaust system is an original Akrapovič product. If there are any doubts, please contact the reseller where the exhaust system was purchased or Akrapovič partners. This manual, any certificates and Akrapovič warranty apply to original products only.
Diagram: Location of the serial number on the muffler's inlet pipe. The serial number format is YYWWPXXXXX.
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, basic guidance on compliance of an Akrapovič exhaust system with various legal requirements can be found on the product-related part of the Akrapovič website (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 the 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. Consult the appropriate laws in the area before installing any aftermarket part or system on a vehicle to ensure compliance with all applicable laws. Neither Akrapovic d.d. nor any of its 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 AND PROTECTIVE EQUIPMENT REQUIRED
- ⚙️ TIGHTENING TORQUE
- ? LUBRICATION
- ? HAND TIGHTEN
- ? INSTALLATION TIP
- ❗ CAUTION OR IMPORTANT
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 of the exhaust system.
WARNING! Avoid eye contact. Keep out of reach of children.
Tools & Equipment
- Mechanic gloves
- T-handle 3 mm hexagon wrench
- T-handle 4 mm hexagon wrench
- T-handle 6 mm hexagon wrench
- T-handle swivelling 2.5 mm hexagon wrench
- T-handle swivelling 3 mm hexagon wrench
- Combination 8 mm wrench
- Combination 10 mm wrench
- T-handle swivelling 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 (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
- Put the motorcycle on a side stand; a central racing stand is recommended. Ensure the surface is solid and flat.
- For Aprilia Tuono V4 only: Unscrew the marked bolts, undo the plastic fastener, and carefully remove the right side cowling of the motorcycle.
CAUTION: Be careful not to injure yourself or damage any part of the motorcycle during this procedure!
Figure 1: Right side cowling removal on Aprilia Tuono V4, showing marked bolts and plastic fastener.
Figure 2: Close-up of right side cowling removal on Aprilia Tuono V4, showing lower marked bolts.
- For Aprilia RSV4 only: Unscrew marked bolts on both sides of the motorcycle, then carefully remove the belly pan of the motorcycle.
CAUTION: Be careful not to injure yourself or damage any part of the motorcycle during this procedure!
Figure 3: Belly pan removal on Aprilia RSV4, showing marked bolts on both sides.
- For Aprilia RSV4 only: Unscrew marked bolts and carefully remove the right side cowling of the motorcycle.
CAUTION: Be careful not to injure yourself or damage any part of the motorcycle during this procedure!
Figure 4: Right side cowling removal on Aprilia RSV4, showing marked bolts.
Figure 5: Close-up of upper marked bolts for right side cowling removal on Aprilia RSV4.
Figure 6: Close-up of lower marked bolts for right side cowling removal on Aprilia RSV4.
Figure 7: Upper marked bolts near handlebars for right side cowling removal on Aprilia RSV4, with inset showing another angle.
Figure 8: Marked bolts near headlight for right side cowling removal on Aprilia RSV4.
- Unscrew marked bolt and loosen marked clamp.
IMPORTANT: Be careful not to damage any part of the motorcycle during this procedure!
Figure 9: Unscrewing bolt and loosening clamp on Tuono V4 exhaust system.
Figure 10: Unscrewing bolt and loosening clamp on RSV4 exhaust system.
- Partially remove stock muffler, loosen marked nuts and carefully remove valve cables off the bracket and muffler. Carefully remove stock muffler off the motorcycle.
CAUTION: Be careful not to injure yourself or damage any part of the motorcycle during this procedure!
Figure 11: Removing valve cables from the stock muffler bracket.
- Unscrew marked bolts and partially remove valve actuator, then disconnect electrical valve connectors from actuator.
IMPORTANT: Be careful not to damage any part of the motorcycle during this procedure!
Figure 12: Unscrewing bolts and partially removing valve actuator.
Figure 13: Disconnecting electrical valve connectors from the actuator.
Figure 14: Another view of disconnecting electrical valve connectors from the actuator.
- Unscrew marked nuts, remove the plastic bracket of the actuator, then disconnect and carefully remove the exhaust valve cables off the actuator and from the motorcycle.
IMPORTANT: Be careful not to damage any part of the motorcycle during this procedure!
Figure 15: Unscrewing nuts and removing plastic bracket of the actuator, showing valve cables.
Figure 16: Another view of removing valve cables from the actuator and motorcycle, with inset showing a different angle.
- 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.
IMPORTANT: Be careful not to damage any part of the motorcycle during this procedure!
Figure 17: Reinstalling the valve actuator without cables, with inset showing a close-up of the actuator.
Installation of the Akrapovič Exhaust System
- 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 of 2.1 Nm (1.5 ft-lb). Notice the marked engravings for determining the correct position.
CAUTION: Be careful not to injure yourself or damage any part of the motorcycle during this procedure!
Figure 18: Installing the bigger spring hook clamp on the Tuono V4 stock collector, showing torque specification.
- 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 of 2.1 Nm (1.5 ft-lb).
CAUTION: Be careful not to injure yourself or damage any part of the motorcycle during this procedure!
Figure 19: Installing the smaller spring hook clamp on the RSV4 stock collector, showing torque specification.
- Install the clamp onto the link pipe's inlet as shown.
IMPORTANT: Hand tighten the clamp only!
Figure 20: Installing the clamp onto the link pipe's inlet, with inset showing a close-up of the clamp.
- Slide the link pipe onto the stock collector, attach the spring and hand tighten the clamp.
IMPORTANT: Make sure that the spring pulls the link pipe all the way onto the stock collector. Use a rubber mallet if necessary to tap the connection into place!
Figure 21: Sliding the link pipe onto the stock collector and attaching the spring.
Figure 22: Close-up of the link pipe connection to the stock collector on Tuono V4, showing spring attachment.
Figure 23: Close-up of the link pipe connection to the stock collector on RSV4, showing spring attachment.
- Correctly position the carbon-fiber clamp (check the position of the yellow sticker) and carefully slide it onto the muffler.
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!
Figure 24: Positioning and sliding the carbon-fiber clamp onto the muffler, showing the yellow sticker for orientation.
- 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.
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 anti-seizing grease (white tube).
Figure 25: Positioning the muffler on the Tuono V4, sliding it onto the link pipe outlet, and attaching springs, with inset showing stock bolt, washer, and threaded bush.
- For Aprilia RSV4 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.
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 anti-seizing grease (white tube).
Figure 26: Positioning the muffler on the RSV4, sliding it onto the link pipe outlet, and attaching springs, with inset showing stock bush, bolt, spacer bush, washer, and nut.
- 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 of 22 Nm (16 ft-lb).
CAUTION: Be careful not to damage any part of the motorcycle or exhaust system during this process!
Figure 27: Aligning and tightening the carbon-fiber clamp on the Tuono V4 muffler bracket to 22 Nm (16 ft-lb).
Figure 28: Aligning and tightening the carbon-fiber clamp on the RSV4 muffler bracket to 22 Nm (16 ft-lb).
- Tighten the clamp to the specified torque of 14 Nm (10 ft-lb).
CAUTION: Be careful not to damage any part of the motorcycle or exhaust system during this process!
Figure 29: Tightening the clamp to 14 Nm (10 ft-lb).
- 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.
- Muffler - titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40® or equivalent)*.
- Muffler - carbon-fiber outer sleeve: use a soft dry cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
- Muffler - carbon-fiber outlet cap: use a soft dry cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
- Painted mufflers and parts: use a soft cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
- Chrome plated mufflers and parts: use a soft cloth sprayed with all purpose foam cleaner, then wipe with a soft dry cloth.
- Stainless steel pipes: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth.
- Titanium pipes: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40® or equivalent)*.
*WD-40® 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 an 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: Akrapovič recommends 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
| Problem | Possible cause | Solution |
|---|---|---|
| Exhaust gas leaks out of the muffler/pipe clamp connections | loosened clamp | tighten the clamp to specified torque |
| Exhaust gas leaks out of the muffler/pipe clamp connections | connection is not completely joined | tap the connection into place and tighten the clamp to specified torque |
