Akrapovič Exhaust System Slip-On Installation Instructions

Introduction

Congratulations on purchasing your Akrapovič product. This manual provides detailed instructions for the installation and use of the Akrapovič Slip-On exhaust system for the Kawasaki Versys 1100.

Akrapovič products are manufactured by Akrapovič d.d., Malo Hudo 8a, 1295 Ivančna Gorica, Slovenia.

Please read this entire manual carefully before proceeding with the installation and use of the Akrapovič product.

For more information, visit the official Akrapovič website: www.akrapovic.com

General Information and Warnings

Safety First

Your safety is paramount. Ride your motorcycle responsibly, safely, and always obey local traffic rules.

Product Compliance and Liability

Akrapovič products are provided "as is". Modifications or improper installation, use, or maintenance contrary to this manual may result in severe damage to the product and/or motorcycle, personal injury, and may affect compliance with legal requirements (e.g., emissions) and warranty coverage. The product must be used in accordance with applicable laws and regulations.

Damage caused by improper installation, use, or maintenance is not covered by the Akrapovič warranty. Refer to the enclosed warranty for terms.

Technical specifications are subject to change without notice.

Copyright and Rights Notice

The Akrapovič trademark, logos, and emblems are protected. Reproduction, manipulation, translation, or other use without explicit written consent from Akrapovič is prohibited. This applies to the entire manual, including specifications, instructions, and graphics.

The shape of the Akrapovič product is protected under Community Design No. RCD 007145206-0001.

Contact local Akrapovič partners or info@akrapovic.com if you suspect a product is not original.

Safety and Compliance Warnings

Before starting installation:

• This manual is specific to the motorcycle indicated on the cover. Installation procedures vary by motorcycle type. Verify the Akrapovič product and manual match your motorcycle.
• For Exhaust System Only: The exhaust system can become extremely hot. Allow it and the engine to cool down completely before installation or any other work. Do not touch the exhaust system until it is cool.
• Ensure the motorcycle is securely positioned to prevent tipping and damage.
• Check received parts against the parts list on the Akrapovič website (look for "Schematic View"). If any parts are missing, do not proceed and contact the retailer.
• Always check your motorcycle's ground clearance. Advanced users may adjust spring preload for optimization.
• For Exhaust System Only: Each muffler has a unique serial number on the inlet pipe to identify authenticity. Verify your exhaust system is an original Akrapovič product. Contact your reseller or Akrapovič partners if in doubt. This manual and warranty apply only to original products.

Diagram: Examples of Serial Number Position (Illustration showing the location of the serial number on the muffler's inlet pipe).

Noise and Emission Warnings

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

USA Warning: Consult appropriate laws before installing aftermarket parts that modify or replace original equipment catalysts. Compliance is the user's responsibility.

California Warning: California law restricts aftermarket parts that modify or replace original equipment catalysts unless an Executive Order has been issued or the part is used only on racing vehicles on closed courses. Purchasers are responsible for understanding and complying with these laws.

General Note and Symbols

Illustrations in this manual are symbolic and may not perfectly match actual components.

Symbols Used:

• TOOLS AND PROTECTIVE EQUIPMENT REQUIRED ?️
• LUBRICATION ?
• INSTALLATION TIP ?
• TIGHTENING TORQUE ?
• HAND TIGHTEN ✋
• CAUTION OR IMPORTANT ⚠️

Product Usage Notes:

• Use Bolt Sealant: Apply 3-4 drops to threads before tightening bolts. Warning: Avoid contact with skin, eyes, mucous membranes. Do not inhale fumes. Keep out of reach of children.
• Use Anti-Seize Lead-Free Copper Paste (black tube): Provides protection against seizing, corrosion, and rust. Warning: Avoid eye contact. Keep out of reach of children.
• Use Anti-Seizing Grease (white tube): Prevents seizing, corrosion, and wear between titanium components. Warning: Avoid eye contact. Keep out of reach of children.

Tools & Equipment

The following tools and equipment are recommended for installation:

• Mechanic gloves
• T-handle 3 mm hexagon wrench
• T-handle 4 mm hexagon wrench
• T-handle 5 mm hexagon wrench
• T-handle 6 mm hexagon wrench
• T-handle 14 mm wrench
• Combination 12 mm wrench
• Combination 14 mm wrench
• Spring puller
• T-handle Torx 45 wrench

Diagram: Illustration of various hand tools, including wrenches and gloves.

Parts List

The packaging box should contain the following items:

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

A detailed list of parts can be found on the Akrapovič website by searching for "Schematic View" on the product page.

Removal of Stock Exhaust System or Other Stock Motorcycle Parts

The process for uninstalling original parts may vary. Consult your motorcycle manufacturer's workshop manual.

Akrapovič is not liable for issues arising from uninstalling stock parts or for the warranty coverage of those parts.

If your Akrapovič system may not be usable under certain conditions, keep your stock exhaust system.

Steps for Removing Stock Exhaust System:

1. Place the motorcycle on a stable, flat central racing stand.
2. Unscrew the marked bracket bolt and loosen the marked clamp. Carefully remove the stock muffler from the motorcycle. ⚠️ CAUTION: Be careful not to injure yourself or damage any part of the motorcycle during this procedure!

Diagram: Images F 01 and F 02 show the rear section of a motorcycle, highlighting the stock exhaust muffler and its mounting points, illustrating the removal process.

Installation of the Akrapovič Exhaust System

1. Assemble the graphite gasket and clamp from the Akrapovič installation kit onto the muffler's inlet, as shown in figures F 03 and F 04. ⚠️ IMPORTANT: Hand tighten the clamp only! ⚠️ IMPORTANT: Make sure not to damage the exhaust system during this process!

Diagram: Figures F 03 and F 04 illustrate the assembly of the muffler inlet with a graphite gasket and clamp.

2. Position the muffler correctly and slide it onto the outlet side of the pre-muffler. Tighten the muffler's bracket to the specified torque (34 Nm / 25 ftlb) using the provided bolt washers and nut from the Akrapovič installation kit, as shown in figure F 05. ⚠️ CAUTION: Be careful not to injure yourself or damage any part of the motorcycle during this procedure!

Diagram: Figure F 05 shows the Akrapovič muffler mounted to the motorcycle, with a close-up of the bracket connection and the specified torque value (34 Nm / 25 ftlb).

3. Tighten the clamp to the specified torque (14 Nm / 10 ftlb), as shown in figure F 06. ⚠️ IMPORTANT: Be careful not to damage the exhaust or any other part of the motorcycle during this process!

Diagram: Figure F 06 shows the clamp connection for the muffler, with the specified torque value (14 Nm / 10 ftlb).

Final Installation and Maintenance

Final Installation Steps:

1. If any Akrapovič product component has a DMC code sticker, remove the sticker and any glue residue before first use.
2. Clean any grease spots off all Akrapovič product surfaces after installation. This prevents spots from burning on. Do not use aggressive chemical cleaners, as they can damage surfaces or stickers. Specific cleaning instructions:
   • 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 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.
3. Ensure all nuts and bolts are sufficiently tightened. If the Akrapovič product contacts the cowling or other parts, readjust the product or contact your authorized dealer.
4. Reinstall any removed stock parts (cowlings, radiator, etc.). Refer to 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. Readjust if the product contacts 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 after replacement is normal.
• ⚠️ IMPORTANT: A change in exhaust system color due to high temperatures is normal.
• ⚠️ CAUTION: Never stand behind the muffler.
• ⚠️ IMPORTANT: Do not use automotive wheel cleaners or cleaning products with 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 and their expected lifetime. Ensure end-of-life products are disassembled and scrapped responsibly according to local laws and regulations. Akrapovič assumes no responsibility for the scrapping process.
• ⚠️ IMPORTANT: In case of contamination with gasoline, immediately wipe all painted/lacquered surfaces with a soft, absorbent cloth.

Troubleshooting