Akrapovič Racing Line Installation Instructions

Introduction and General Information

Congratulations on purchasing your Akrapovič product, manufactured by Akrapovič d.d., Malo Hudo 8a, 1295 Ivančna Gorica, Slovenia.

Please read this entire installation manual carefully before installing and using the product. Installation should only be performed by individuals skilled in motorcycle exhaust system or parts installation. Failure to follow instructions may void warranty and lead to damage or injury. For questions, contact your local Akrapovič partner.

Your safety is paramount. Ride responsibly and obey traffic rules.

Product compliance statements are made on an "as is" basis. Modifications or improper installation/use may cause severe damage, personal injury, and affect legal compliance (e.g., emissions) and warranty coverage. Use the product only in accordance with applicable laws.

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, or translation of this manual's content, including technical specifications and illustrations, is prohibited without explicit written consent from Akrapovič.

The product's design is protected under Community Design No. RCD 002747246-001.

Akrapovič takes infringement seriously. For concerns about product authenticity, contact local partners or info@akrapovic.com.

Safety and Compliance Warnings

Before starting installation, verify all items listed:

• This manual is specific to the Yamaha YZF-R7. Installation procedures vary by motorcycle type.
• For Exhaust System Only: The exhaust system becomes extremely hot. Allow it to cool completely before touching. Cool the exhaust and engine before starting any work.
• Ensure the motorcycle is securely positioned to prevent tipping and damage.
• Check received parts against the parts list on the Akrapovič website (use QR code or search "Schematic view"). Contact the retailer if any parts are missing before proceeding.
• Always check your motorcycle's ground clearance. Advanced users may adjust spring preload for optimal clearance.
• For Exhaust System Only: Each muffler has a unique serial number on the inlet pipe for authenticity verification. Ensure your system is an original Akrapovič product.

Example of Serial Number Position: The serial number is located on the muffler's inlet pipe.

Noise and Emission Warnings

General Warning: Purchasers are responsible for understanding and complying with local air and noise emission laws for the jurisdiction where the product will be used.

USA Warning: Consult state and federal laws regarding aftermarket parts that modify, remove, or replace original equipment catalysts.

California Warning: California law restricts aftermarket parts that modify or replace original catalysts unless an Executive Order is issued by the California Air Resources Board or the part is used exclusively for racing on closed courses.

General Note and Symbols

Illustrations in this manual are symbolic and intended to aid understanding. Actual components may differ slightly.

Symbols Used:

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

Specific Product Usage Notes:

• Bolt Sealant: Apply 3-4 small drops to cleaned, degreased threads before tightening bolts. Warning: Avoid skin/eye contact, do not inhale fumes, keep away from children.
• Anti-Seize Lead-Free Copper Paste: Protects against seizing, corrosion, and rusting of bolts, threaded ends, nuts, and joints. Also protects against vibration, wear, and impact. Warning: Avoid eye contact, keep away from children.
• 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
• Spring puller
• Small crosshead screwdriver
• T-handle 4 mm hexagon wrench
• T-handle 6 mm hexagon wrench
• Torx 30 wrench
• Torx 40 wrench
• Torx 45 wrench
• Combination 10 mm wrench
• Combination 13 mm wrench
• Combination 17 mm wrench
• T-handle swivelling 12 mm wrench

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.

Removal of Stock Exhaust System or Other Stock Motorcycle Parts

The process for removing original parts may vary. Refer to the motorcycle manufacturer's workshop manual. Akrapovič is not liable for issues arising from incorrect removal or warranty coverage of stock parts.

Retain stock parts for potential use on public roads if the Akrapovič system is not street-legal in your area.

Step-by-step Removal:

1. Place the motorcycle on its side stand or a central racing stand on a solid, flat surface.
2. Undo marked plastic fasteners, unscrew marked bolts, and carefully remove the ride side of the cowling (Refer to Figure F01, F02). Caution: Be careful not to injure yourself or damage the motorcycle.
3. Unscrew marked bolts and carefully remove the lower part of the cowling (Refer to Figure F03). Caution: Be careful not to injure yourself or damage the motorcycle.
4. Unscrew the lambda sensor (Refer to Figure F04). Caution: Be careful not to injure yourself or damage the motorcycle. Important: Do not damage the lambda sensor's electrical lead.
5. Unscrew marked flange nuts and muffler's bracket bolts, then carefully remove the exhaust system (Refer to Figure F05, F06). Important: Support the exhaust system during removal. Caution: Be careful not to injure yourself or damage the motorcycle.
6. Unscrew marked bolts and carefully remove the chassis cover (Refer to Figure F07). Caution: Be careful not to injure yourself or damage the motorcycle.
7. Undo the plastic clip, disconnect the lambda sensor connector, and remove the lambda sensor (Refer to Figure F08, F09). Important: Do not damage the lambda sensor's electrical lead. Caution: Be careful not to injure yourself or damage the motorcycle.
8. Unscrew marked bracket bolts and remove the bracket (Refer to Figure F10). Caution: Be careful not to injure yourself or damage the motorcycle.

Installation of the Akrapovič Exhaust System

1. Install the bracket back onto the motorcycle. Tighten to the specified torque (9.8 Nm / 7 ftlb) using additional spacer bushes and bolts from the Akrapovič installation kit (Refer to Figure F11). Important: Use bolt sealant on marked bolt threads. Caution: Be careful not to injure yourself or damage the motorcycle.
2. Unscrew the stock nut. Install the additional muffler bracket from the Akrapovič installation kit. Tighten to the specified torque using the stock nut, bolt, and washer from the Akrapovič installation kit (Refer to Figure F12, F13, F14). Important: Use bolt sealant on marked bolt threads. Caution: Be careful not to injure yourself or damage the motorcycle.
3. Insert the Akrapovič catalytic converter into the header's outlet (Refer to Figure F15). Important: EC Type Approval is valid only if the catalytic converter is installed.
4. Assemble the headers with the Link-pipe and attach the springs on both sides (Refer to Figure F16, F17). Important: Ensure springs pull the link-pipe fully onto the headers; use a rubber mallet if necessary.
5. Assemble the bracket onto the pre-muffler. Tighten to the specified torque (22 Nm / 16 ftlb) using bolts from the Akrapovič installation kit (Refer to Figure F18). Important: Use bolt sealant on all four bolt threads.
6. Position the pre-muffler correctly and slide it onto the outlet side of the link-pipe, then attach the springs (Refer to Figure F19). Important: Ensure springs pull the pre-muffler fully onto the link-pipe; use a rubber mallet if necessary. Caution: Be careful not to injure yourself.
7. Install the headers with the pre-muffler onto the motorcycle. Hand tighten the flanges onto the cylinder head using stock nuts (Refer to Figure F20). Important: Support the exhaust system. Important: Do not fully tighten the flanges yet. Installation Tip: Use new stock exhaust port gaskets.
8. Position the pre-muffler correctly and hand tighten it using stock bolts onto the motorcycle (Refer to Figure F21). Important: Be careful not to injure yourself or damage the motorcycle.
9. Install the clamp from the Akrapovič installation kit onto the muffler as shown (Refer to Figure F22). Important: Be careful not to injure yourself or damage the exhaust.
10. Position the muffler correctly, slide it onto the pre-muffler, attach the spring, and hand tighten the muffler's bracket using bolt washers and nut from the Akrapovič installation kit (Refer to Figure F23). Important: Ensure springs pull the muffler fully onto the pre-muffler; use a rubber mallet if necessary. Important: Be careful not to injure yourself or damage the motorcycle.
11. Connect the lambda sensor extension cord (Akrapovič installation kit) to extend the lambda sensor's electric lead and reinstall the lambda sensor connector (Refer to Figure F24, F25). Important: Do not damage the lambda sensor's electrical lead.
12. Plug the lambda sensor connector into the Akrapovič extension cord, reroute the lambda sensor's electric lead, and tighten the lambda sensor into the header to the specified torque (34 Nm / 25 ftlb). Secure the connector and lead using zip ties from the Akrapovič installation kit (Refer to Figure F26, F27, F28). Important: Do not damage the lambda sensor's electrical lead.
13. Position the muffler correctly. Tighten the muffler's bracket bolt and clamp to the specified torques (14 Nm / 10 ftlb for clamp, 22 Nm / 16 ftlb for bracket bolt) (Refer to Figure F29). Important: Be careful not to injure yourself or damage the motorcycle.
14. Tighten the pre-muffler's bracket bolts to the specified torque (22 Nm / 16 ftlb) (Refer to Figure F30). Important: Be careful not to injure yourself or damage the motorcycle.
15. Tighten the flange nuts to the specified torque (22 Nm / 16 ftlb) (Refer to Figure F31). Important: Be careful not to damage the exhaust or any other part of the motorcycle.
16. Reinstall all dismounted stock parts and cowlings in the reverse order of removal. Installation Tip: Check vehicle manufacturer manual for tightening torques. Caution: Be careful not to damage any part of the motorcycle.

Final Installation

1. Clean grease spots off all Akrapovič product surfaces after installation. Avoid aggressive chemical cleaners. Specific cleaning advice:
   • Titanium surfaces: Use a soft cloth sprayed with a multi-purpose spray lubricant (e.g., WD-40®), then wipe with a soft dry cloth.
   • Carbon-fiber surfaces: Use a soft dry cloth sprayed with all-purpose foam cleaner, then wipe with a soft dry cloth.
   • Painted surfaces: Use a soft cloth sprayed with all-purpose foam cleaner, then wipe with a soft dry cloth.
   • Chrome plated surfaces: Use a soft cloth sprayed with 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.

2. Ensure all nuts and bolts are sufficiently tightened. If the Akrapovič product touches the cowling or other parts, adjust its position or contact your authorized dealer.
3. Reinstall all removed stock parts (cowlings, radiator, etc.). Consult the vehicle manufacturer's workshop manual for correct procedures and tightening torques.

Maintenance of the Akrapovič Product

• Important: Periodically check that all bolts and springs are sufficiently tightened. Adjust if the product touches the cowling or other parts, or contact your authorized dealer.
• Caution: After running the engine for 30 minutes, retighten the bolts of the Akrapovič carbon-fiber heat shield.
• Important: White smoke from the muffler during the first 100 km of use is normal.
• Important: Changes in exhaust system color due to high temperatures are 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 paint/lacquer damage.
• Important: Akrapovič products are designed for specific vehicles for their lifetime. Ensure end-of-life products are disassembled and components scrapped responsibly according to applicable local laws and regulations. Akrapovič assumes no responsibility for the scrapping process or related information.

Troubleshooting