Akrapovič Racing Line Exhaust System Installation Guide

Introduction

Congratulations on purchasing the Akrapovič product. This manual provides detailed instructions for installing the Akrapovič Racing Line exhaust system on the Kawasaki Ninja ZX-6R.

The Akrapovič product is manufactured by Akrapovič d.d., Malo Hudo 8a, 1295 Ivančna Gorica, Slovenia.

Important: Please read this entire manual carefully before installation and use. Installation should only be performed by individuals skilled in motorcycle exhaust system or parts installation.

Akrapovič and its partners are not liable for any damage or injury resulting from improper installation, use, or maintenance contrary to these instructions.

For questions, contact your local Akrapovič partner or visit www.akrapovic.com for more information.

General Information

Safety First: Ride your motorcycle responsibly and obey traffic rules.

Product compliance statements are made on an "as is" basis. Modifications or improper installation/use may lead to severe damage, personal injury, and affect compliance with legal requirements (e.g., emissions) and warranty coverage.

The product must be used in accordance with all applicable laws and regulations.

Damage from improper installation, use, or maintenance is not covered by the Akrapovič warranty. Refer to the enclosed warranty document for details.

Technical specifications are subject to change without notice.

Copyright and Other Rights Notice

The Akrapovič trademark, logos, and emblems are protected by copyright and trademark rights.

Reproduction, manipulation, translation, or other use of these rights is prohibited without explicit written consent from Akrapovič.

The product shape is protected under Community Design No. RCD 002747329-0001.

For suspected non-original products, contact local partners or info@akrapovic.com.

Safety and Compliance Warnings

Before starting installation:

• Manual Specificity: This manual is specific to the motorcycle indicated on the cover. Installation procedures vary by motorcycle type. Verify compatibility.
• Exhaust Heat: The exhaust system becomes extremely hot. Allow it and the engine to cool completely before installation or any work. Do not touch until cool.
• Motorcycle Stability: Ensure the motorcycle is securely positioned to prevent tipping.
• Parts Check: Verify all received parts against the parts list on the Akrapovič website (look for "Schematic View"). If parts are missing, do not proceed and contact the retailer.
• Ground Clearance: Always check your motorcycle's ground clearance. Consider adjusting spring preload for optimization.
• Serial Number: Each muffler has a unique serial number on the inlet pipe for authenticity. Verify your product is original. Contact reseller or Akrapovič if in doubt. This manual and warranty apply only to original products.

Serial Number Position Example:

Image shows a diagram illustrating the typical location of a serial number on the muffler's inlet pipe.

Noise and Emission Warnings

General: Akrapovič d.d. and its subsidiaries do not represent that products comply with air/noise emissions laws of any jurisdiction. Purchasers are responsible for informing themselves and complying with applicable laws.

Compliance Guidance: Basic compliance guidance is available on the Akrapovič website. For EC/ECE type approvals, refer to the enclosed certificate.

USA Warning: Individual U.S. states and the federal government have laws regulating aftermarket parts that modify or replace original equipment catalysts. Consult local laws before installation.

California Warning: California law prohibits the use of aftermarket parts that modify or replace original equipment catalysts unless an Executive Order has been issued by the California Air Resources Board or the part is used solely for racing on closed courses. Purchasers must inform themselves and comply with California laws.

General Note and Symbols

Illustrations are symbolic and intended to aid installation steps. Actual components may vary slightly.

Symbols Used:

• Tools and Protective Equipment Required: ?
• Tightening Torque: ?️
• Lubrication: ?️
• Hand Tighten: ✋
• Installation Tip: ?
• Caution or Important: ⚠️

Special Instructions:

• Use Bolt Sealant: Apply 3-4 small drops of bolt sealant to clean, degreased threads before tightening. WARNING: Avoid contact with skin/eyes, do not inhale fumes, keep out of reach of children.
• Use Anti-Seize Lead-Free Copper Paste: Provides protection against seizing, corrosion, and rust. WARNING: Avoid eye contact, keep out of reach of children.
• Use Anti-Seizing Grease: Prevents seizing, corrosion, and wear between titanium components. WARNING: Avoid eye contact, keep out of reach of children.

Tools & Equipment Required

• Mechanic gloves
• T-handle 10 mm wrench
• T-handle swivelling 10 mm wrench
• T-handle swivelling 12 mm wrench
• T-handle 4 mm hexagon wrench
• T-handle 5 mm hexagon wrench
• T-handle 6 mm hexagon wrench
• Combination 8 mm wrench
• Combination 17 mm wrench
• Spring puller

Parts List

The packaging box should contain:

• Akrapovič product
• Homologation certificate/compliance documents (if applicable)
• Warranty
• Fitting material
• Installation Manual

A detailed parts list is available on the Akrapovič website under "Schematic View".

Removal of Stock Exhaust System

Step 1: Prepare the Motorcycle

Place the motorcycle on a side stand or central racing stand on a solid, flat surface.

Step 2: Remove Seats

Remove both seats from the motorcycle (See Figure F01).

Figure F01: Image shows the rear of the motorcycle with arrows indicating the removal of both seats.

⚠️ CAUTION: Be careful not to injure yourself or damage the motorcycle.

Step 3: Remove Right Side Plastic Cowling

Unscrew marked bolts and undo marked plastic fasteners. Carefully remove the right side plastic cowling (See Figure F02).

Figure F02: Image shows the right side plastic cowling with arrows pointing to bolts and fasteners to be removed.

⚠️ CAUTION: Be careful not to injure yourself or damage the motorcycle.

Step 4: Undo Servo Valve Cable Bracket

Undo the servo valve's cable bracket (See Figure F03).

Figure F03: Image shows a close-up of the servo valve cable bracket, with an arrow indicating the bracket to be undone.

❗ IMPORTANT: Be careful not to injure yourself or damage the motorcycle.

Step 5: Adjust Servo Valve Cable

Slide the rubber protection off the servo valve's cable adjuster. Loosen the nuts and shorten the adjuster as shown (See Figure F04).

Figure F04: Image shows the servo valve cable adjuster with rubber protection removed. An inset shows a close-up with nuts to be loosened and an arrow indicating shortening the adjuster.

⚠️ CAUTION: Be careful not to injure yourself or damage the motorcycle.

Step 6: Remove Muffler Heat Shield

Unscrew marked bolts and remove the heat shield from the muffler (See Figure F05).

Figure F05: Image shows the rear muffler with arrows pointing to bolts securing the heat shield.

⚠️ CAUTION: Be careful not to injure yourself or damage the motorcycle.

Step 7: Remove Exhaust Valve Cables

Unscrew marked nuts and remove the cables from the exhaust valve (See Figure F06).

Figure F06: Image shows the exhaust valve area with arrows pointing to nuts and cables to be removed from the exhaust valve.

⚠️ CAUTION: Be careful not to injure yourself or damage the servo valve's cables.

Step 8: Remove Muffler

Loosen the marked clamp, unscrew the muffler's bracket bolt, and carefully remove the muffler (See Figures F07, F08).

Figure F07: Image shows the muffler mounting point with an arrow indicating the bracket bolt to unscrew.

Figure F08: Image shows the muffler being removed from the motorcycle.

⚠️ CAUTION: Be careful not to injure yourself or damage the motorcycle.

Step 9: Remove Cables

Unhook the marked safety bracket and unhook/remove the cables from the motorcycle (See Figures F09, F10).

Figure F09: Image shows the area where safety brackets and cables are located, with an arrow pointing to the safety bracket.

Figure F10: Image shows cables being unhooked and removed.

⚠️ CAUTION: Be careful not to injure yourself or damage the motorcycle.

Step 10: Remove Pre-Muffler Heat Shield

Unscrew marked bolts and remove the heat shield from the pre-muffler (See Figure F11).

Figure F11: Image shows the pre-muffler area with arrows pointing to bolts securing the heat shield.

⚠️ CAUTION: Be careful not to injure yourself or damage the motorcycle.

Step 11: Remove Right Side Plastic Cowling (Engine Area)

Unscrew marked bolts and undo marked plastic fasteners. Carefully remove the right side plastic cowling (See Figure F12).

Figure F12: Image shows the right side of the motorcycle engine area with arrows pointing to bolts and plastic fasteners on the cowling.

⚠️ CAUTION: Be careful not to injure yourself or damage the motorcycle.

Step 12: Remove Lambda Sensors

Unscrew both lambda sensors from the exhaust system (See Figure F13).

Figure F13: Image shows the exhaust headers with lambda sensors. Arrows indicate the lambda sensors to be unscrewed.

❗ IMPORTANT: Make sure not to damage the lambda sensors' electrical leads.

Step 13: Remove Stock Exhaust

Unscrew all header flange nuts and the marked bracket bolt. Carefully remove the stock exhaust (See Figures F14, F15).

Figure F14: Image shows the exhaust headers connected to the engine, with arrows indicating the header flange nuts and bracket bolt to be unscrewed.

Figure F15: Image shows the stock exhaust being removed from the motorcycle.

⚠️ CAUTION: Be careful not to injure the radiator or any other part of the motorcycle.

❗ IMPORTANT: Support the exhaust during removal.

Installation of the Akrapovič Exhaust System

Step 1: Install Headers

Set up and hand-tighten the flanges with springs and sleeves onto the cylinder head using stock nuts. Ensure correct orientation of flanges and springs (See Figure F16).

Figure F16: Image shows the cylinder head area with exhaust port gaskets. An arrow indicates the orientation of flanges and springs being hand-tightened onto the cylinder head.

❗ IMPORTANT: Do not fully tighten the flanges yet.

? INSTALLATION TIP: Use new stock exhaust port gaskets.

Step 2: Attach Headers and Springs

Insert the headers into the sleeves and attach the springs (See Figures F17, F18).

Figure F17: Image shows the headers being inserted into sleeves.

Figure F18: Image shows springs attached to the header tubes and sleeves. An arrow highlights the spring connection.

❗ IMPORTANT: Ensure springs pull header tubes fully into sleeves. Use a rubber mallet if necessary.

❗ IMPORTANT: Be careful not to damage the radiator or any other part of the motorcycle.

Step 3: Slide Link Pipe and Attach Springs

Slide the link pipe onto the headers and attach the springs (See Figure F19).

Figure F19: Image shows the link pipe being slid onto the headers and springs attached. An arrow indicates the spring connection.

❗ IMPORTANT: Ensure springs pull the link pipe fully onto the headers. Use a rubber mallet if necessary.

❗ IMPORTANT: Be careful not to injure yourself or damage the motorcycle.

Step 4: Position and Slide Carbon Fiber Clamp

Correctly position the carbon fiber clamp (note the clamp sticker's position) and slide it onto the muffler (See Figure F20).

Figure F20: Image shows the muffler with a carbon fiber clamp being positioned and slid onto it. An arrow indicates the clamp sticker's correct position.

⚠️ CAUTION: Open the clamp slightly wider than the muffler sleeve diameter. Do not scrape the outer sleeve.

Step 5: Position Muffler and Tighten Bracket

Position the muffler correctly, slide it onto the link pipe, and attach the spring. Hand-tighten the muffler's bracket using the provided bolt, washers, and nut from the Akrapovič installation kit (See Figure F21).

Figure F21: Image shows the muffler positioned correctly and attached to the link pipe. Arrows indicate the spring and the muffler bracket bolt.

❗ IMPORTANT: Ensure springs pull the muffler fully onto the link pipe. Use a rubber mallet if necessary.

⚠️ CAUTION: Be careful not to injure yourself or damage the motorcycle.

Step 6: Install and Tighten Lambda Sensors

Install the lambda sensors into the collectors and tighten them to the specified torque (See Figure F22).

Figure F22: Image shows the exhaust collectors with lambda sensors being installed. Torque specifications (34Nm / 25ftlb) are indicated.

❗ IMPORTANT: Make sure not to damage the lambda sensors' electrical leads.

Step 7: Tighten Muffler Bracket

Align the muffler with the motorcycle and tighten the muffler's bracket bolt to the specified torque (See Figure F23).

Figure F23: Image shows the muffler bracket connection. A bolt is indicated, with torque specifications (22Nm / 16ftlb).

❗ IMPORTANT: Be careful not to damage the exhaust or any other part of the motorcycle.

Step 8: Tighten Header Flange Nuts

Tighten the header's flange nuts to the specified torque (See Figure F24).

Figure F24: Image shows the exhaust headers connected to the engine. Arrows indicate the header flange nuts (8x) with torque specifications (22Nm / 16ftlb).

Step 9: Reinstall Stock Parts

Reinstall all removed plastic cowlings in the reverse order of removal. Consult the motorcycle manufacturer's workshop manual for correct procedures and tightening torques.

❗ IMPORTANT: Be careful not to damage the radiator or any other part of the motorcycle.

Final Installation

Cleaning:

Clean any grease spots off all Akrapovič product surfaces after installation. This prevents spots from burning on. Avoid aggressive chemical cleaners that can damage surfaces or stickers.

• Titanium Surfaces: Use a soft cloth sprayed with a multi-purpose spray lubricant (e.g., WD-40®) and wipe with a soft dry cloth.
• Carbon-fiber Surfaces: Use a soft dry cloth sprayed with an all-purpose foam cleaner, then wipe with a soft dry cloth.
• Painted Surfaces: Use a soft cloth sprayed with an all-purpose foam cleaner, then wipe with a soft dry cloth.
• Chrome Plated Surfaces: Use a soft cloth sprayed with an all-purpose foam cleaner, then wipe with a soft dry cloth.
• Stainless Steel Surfaces: 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.

Final Checks:

Ensure all nuts and bolts are sufficiently tightened. If the Akrapovič product contacts other parts, adjust its position or contact an authorized dealer.

Reinstall all removed stock parts (cowlings, radiator, etc.), following the motorcycle manufacturer's workshop manual for procedures and torques.

Maintenance of the Akrapovič Product

• ❗ IMPORTANT: Periodically check and tighten all bolts and springs. Adjust product position if it contacts other parts, or contact an authorized dealer.
• ⚠️ CAUTION: After the engine has run for 30 minutes, retighten the bolts of the Akrapovič carbon-fiber heat shield.
• ❗ IMPORTANT: White smoke from the muffler during the first 100 km is normal.
• ❗ IMPORTANT: A change in exhaust system color due to high temperatures is normal.
• ⚠️ CAUTION: Do not stand behind the muffler at any time.
• ❗ IMPORTANT: Do not use automotive wheel cleaners or cleaning products containing acidic additives.
• ❗ IMPORTANT: Use caution when using power/pressure washers on painted/lacquered surfaces to avoid damage.
• ❗ IMPORTANT: Akrapovič products are designed for specific vehicles. At end-of-life, disassemble components as per the schematic diagram on the website and scrap responsibly according to local laws. Akrapovič is not responsible for scrapping processes or related information.

Troubleshooting