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Installation instructions

Akrapovič Exhaust SystemSlip-Onfor theYAMAHA X-MAX 125/250, X-CITY 125/250

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Congratulations on purchasing an Akrapovič exhaust system. Please read the entire installation manual prior to undertaking any activities related to installation of your new Akrapovič exhaust system. In case you do not fully understand the manual or any of its parts, please contact your authorized dealer!

This product should be installed by someone with sufficient knowledge of exhaust systems and their installation, and appropriate hand or power tools. If you are not qualified for this work, please utilize a certified mechanic for installation. By installing Your Akrapovič exhaust system, you indicate that you have read the installation manual in its entirety and you agree with the terms stated herein.

It is your responsibility to follow all installation instruction guidelines supplied with the Akrapovič exhaust system and undertake all necessary safety precautions. Akrapovič d.d. assumes no responsibility for damages occurring from misuse, abuse, improper installation, improper operation, lack of responsible care, or all previously stated reasons resulting from incompatibility with other manufacturer’s products and/or systems.

IMPORTANT INFORMATION

Exclusion of Certain Liability1. Themanufacturer,importerordealershallnotbeliableforanyincidentaldamageincludingpersonalinjury

oranyotherdamagescausedbyimproperinstallationoroperationoftheAkrapovičexhaustsystem.Wheninstalling theAkrapovič exhaust systembe careful that the exhaust systemdoes not touch other partssensitivetohightemperature.

2. Akrapovičmakesnorepresentationorwarrantieswithregardtodamagecausedbytheimproperinstallation,useandmaintenanceoftheAkrapovičexhaustsystem.Thewarrantyislimitedtodefectsrecognizedbyourtechnicaldepartmentandduetonormaluse,andexcludesitemssubjecttonormalwear(gasketsanddampingwool).Theguaranteeisvoidincaseofaccident,modification,improperorcompetitionuse.

3. Donotattempttoinstall theAkrapovičexhaustsystemonavehiclemodelforwhichitwasnotmadeortestedbyAkrapovič.

4. Whentheexhaustsystemgetsveryhotduringoperation,becarefulnottoburnyourselfontheexhaustsystemorpartswhichareindirectcontactwithit,evenwhentheengineisnotrunning.Alsoprotectotherpeople,especiallychildren,fromtheinjuriesmentionedabove.

5. InsomecasesAkrapovičexhaustsystemkitscontainchemicalproducts(ceramicanti-seizinggrease;boltsealant).Handlewithcare,donot inhaleorswallow.Avoidexcessivecontactwithskin,eyesormucousmembranes.Keepoutofreachofchildren.

6. TechnicalspecificationsofAkrapovičexhaustsystemsandrelatedproductsaresubjecttochangewithoutnotice.

7. Before removing theoriginalexhaustsystemfromyourvehicle,pleasecompare thepartsyoureceivedwiththelistofmaterialsprovidedintheinstallationmanualinordertoassurethatyouhaveallthepartsnecessaryfortheinstallationofyournewAkrapovičexhaustsystem.

8. Although thismanualconsistsof instructions for installation inwritten form,aswellasphotographsandpictures representing individual stepsof the installation, pleasenote that thephotographsandpicturesaresymbolicandareintendedforrepresentationofgeneraloverviewonly.Thephotographsandpicturescontainedhereinshouldserveasaguidelineonlyandactual installationoftheexhaustsystemmaynotcorrespondwiththephotographsandpicturesentirely.

9. Theprocessofuninstallingtheoriginalexhaustsystemmayvarydependingontheexistingexhaustsystem.Pleasefollowtheoriginalexhaustsystemmanufacturer’sinstructionsforuninstallingtheoriginalexhaustsystem.

TrademarksTheAkrapovičExhaustSystemTechnologylogoisaregisteredtrademarkofAkrapovičd.d.

Akrapovič websiteInformationaboutAkrapovičexhaustsystemsandrelatedproductsisavailableontheAkrapovičwebsiteat:http://www.akrapovic.com/

CopyrightNopartoftheAkrapovičexhaustsystemoritsdocumentationmaybereproducedordistributedinanyformorbyanymeanswithoutthepriorwrittenauthorizationoftheAkrapovičcompany.

©Akrapovič,d.d.Allrightsreserved.

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CAUTIONORWARNINGINSTALLATION TIP

TOOLS REQUIRED TIGHTENING TORQUE

SymbolsThefollowingsymbolsareusedthroughouttheseinstallationinstructions:

USE BOLT SEALANT;Apply3to4smalldropsofboltsealantontothecleanedanddegreasedthreadsbeforetighteningthebolts.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(blacktube);Providestrouble-freeandlong-lastingprotectionagainstseizing,corrosionandrustingofbolts,threadedends,nuts,joints,etc.Alsoprotectsagainstvibration,wearandimpact. WARNING! Avoid eye contact. Avoid excessive skin contact. Keep out of reach of children.

USE ANTI-SEIZING GREASE(whitetube);Preventsseizing,corrosionandexcessivewearbetweenthetitaniumcomponentsofyourexhaustsystem.WARNING! Avoid eye contact. Avoid excessive skin contact. Keep out of reach of children.

T-handle 5 mm three hexagon key wrenchT-handle 10 mm wrenchT-handle 12 mm wrenchT-handle 13 mm wrenchT-handle 14 mm wrenchT-handle 17 mm wrenchSpring puller

BEFORE INSTALLING, CHECK SCHEMATIC OF THE EXHAUST SYSTEM!

IF ANY ITEMS IN THE AKRAPOVIČ EXHAUST SYSTEM PACKAGE ARE MISSING, PLEASE CONTACT YOUR AUTHORIZED DEALER. KEEP THE SCHEMATIC FOR FUTURE REFERENCE.

THESE INSTALLATION INSTRUCTIONS MUST BE READ CAREFULLY IN ORDER TO ENSURE PROPER INSTALLATION AND OPERATION OF THE AKRAPOVIČ EXHAUST SYSTEM.

THE EXHAUST SYSTEM CAN BE EXTREMELY HOT. ALLOW THE EXHAUST AND ENGINE TO COOL DOWN BEFORE BEGINNING INSTALLATION.

WE ADVISE YOU TO LEAVE INSTALLATION TO A QUALIFIED SERVICEMAN. IMPROPER INSTALLATION MAY RESULT IN A SHORTER LIFETIME OF THE EXHAUST SYSTEM AND/OR DAMAGE TO THE VEHICLE.

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Figure 1

Figure 2

1.2.

For X-MAX250 / X-CITY250 only:unscrewthemarkedrearbrakecaliper bolts (Figure 2).3.

Putthemotorcycleonasidestand,werecommendaracingstand.Makesure,thatsurfaceissolidandflat.Untightenthemarkedboltofthelinkpipeclamp,unscrewthemarkedmufflerbraketboltsandremovethestockmuffleroffthemotorcycle(Figure 1).

REMOVAL OF STOCK EXHAUST SYSTEM:

Figure 4

34Nm25ftlb

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Figure 3

4. For X-MAX125 / X-CITY125 only:unscrewthemarkedrearbrakecaliperbolts (Figure 3).

For X-MAX250 / X-CITY250 only: install theAkrapovičmufflerbracketonto thebrakecaliperasshown,usingAkrapovičboltsandwashers.Tightentheboltstoaspecifiedtorque.InserttheAkrapovičPVCplugsintothestockmuffler’smountingholes,userubbermallettotaptheplugsintoplace (Figure 4).WARNING: use Akrapovič bolt sealant on the marked bolt threads!

1.

INSTALLATION OF THE AKRAPOVIČ EXHAUST SYSTEM:

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22Nm16ftlb

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Figure 5

Figure 6

CorrectlyinstallAkrapovičmetalclampontotheAkrapovičlinkpipeandinsertthecatalystintothelinkpipeasshown(Figure 6).WARNING: use anti-seize copper paste on bolt threads of the metal clamp!WARNING: make sure that you put the longer part of the catalyst into the link pipe!

For X-MAX125 / X-CITY125 only: install theAkrapovičmufflerbracketonto thebrakecaliperasshown,usingAkrapovičboltsandwashers.Tightentheboltstoaspecifiedtorque.InserttheAkrapovičPVCplugsintothestockmuffler’smountingholes,userubbermallettotaptheplugsintoplace (Figure 5).WARNING: use Akrapovič bolt sealant on the marked bolt threads!

2.

3.

Figure 8

22Nm16ftlb

9.8Nm7ftlb

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CorrectlypositionandslidetheAkrapovičlinkpipeontothestockheaderandhandtightenthemetalclamp(Figure 7).CAUTION: Do not fully tighten the metal clamp yet!

PositionthemufflercorretlyandslideitontotheoutletsideofAkrapovičlinkpipeandattachthesprings.Alignthemufflerinrespectthemotorcycleandtightenthemuffler’sbracketbolt,usingAkrapovičboltandwasher.TightenthemetalclampattheAkrapovičlinkpipe/stockheaderpipejointtoaspecifiedtorque(Figure 8).

5.

4.

Figure 7

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IT IS NORMAL IF WHITE SMOKE COMES OUT OF THE MUFFLER ON FIRST OPERATION.

DO NOT STAND BEHIND THE MUFFLER ON FIRST OPERATION. DO NOT USE AUTOMOTIVE WHEEL CLEANERS OR ANY CLEANING PRODUCTS WHICH CONTAIN ACIDIC ADDITIVES TO CLEAN AKRAPOVIČ EXHAUST SYSTEMS.

1. Cleanthetitaniumexhaustcomponentswithamulti-purposespraylubricant(WD-40orequivalent),carbonfiberexhaustcomponentswithsoftanddryclothandstainlesssteelcomponentswithsoftclothsprayedwithcontactcleaner,thenwipewithsoftanddrycloth.Achangeinthecoloroftheexhaustsystemisnormalduetothehightemperatures.

2. Periodicallymakesurealltheboltsandspringsaresufficientlytight.

WARNING: make sure all the bolts are sufficiently tightened. In case the exhaust system touches thecowling or other parts repeat the adjustment of the exhaust system or contact your authorized dealer.

MAINTENANCE OF THE AKRAPOVIČ EXHAUST SYSTEM:

Final installation:

WARNING: check vehicle manufacturer manual for tightening torques (for dismounted stock parts)!

Cleangreasespots:a. Muffler–stainlesssteeloutersleeve:useasoftclothsprayedwithamulti-purposespraylubricant(WD-

40orequivalent).b. Muffler–carbon-fiberoutletcap:useasoftdrycloth.c. Linkpipe-stainlesssteellinkpipe:useasoftclothsprayedwithacontactcleaner,thenwipewithasoft

drycloth.

Cleaningwillpreventspotsfromburningontothesurface.Donotuseaggressivechemicalcleaners,becausetheycandamagethesticker.

YAMAHA X-MAX250 / X-CITY 250 / Slip-ON system / STREET LEGAL Product number: S-Y2SO4-HRSS

P-HF542 BRACKET SET

P-HF263 FITTING KIT

P-KAT028 CATALYTIC CONVERTER (OPTIONAL)

P-S2 SPRINGL-Y2SO1SS LINK PIPE

P-R51 CLAMP

M-HR02602SS MUFFLER WITH STAINLESS STEEL OUTER SLEEVE

V-TUV019 NOISE REDUCTION INSERT

P-HST2AL STICKER

P-TT45 BELT

V-EC146 END CAP SET

P-TT45 BELT

P-X66 MUFFLER BRACKET

P-HF267 LOCKTITE

MUFFLER REPAIR KITS

KIT Part Nr.

REPACK P-RPCK26

SLEEVE P-RKS300RSS35

YAMAHA X-MAX125 / X-CITY125 / Slip-ON system / STREET LEGAL Product number: S-Y125SO1-HRSS

P-HF546 BRACKET SET

P-HF263 FITTING KIT

P-KAT028 CATALYTIC CONVERTER (OPTIONAL)

P-S2 SPRINGL-Y125SO1SS LINK PIPE

P-R51 CLAMP

M-HR02602SS MUFFLER WITH STAINLESS STEEL OUTER SLEEVE

V-TUV019 NOISE REDUCTION INSERT

P-HST2AL STICKER

P-TT45 BELT

V-EC146 END CAP SET

P-TT45 BELT

P-X67 MUFFLER BRACKET

P-HF267 LOCKTITE

MUFFLER REPAIR KITS

KIT Part Nr.

REPACK P-RPCK26

SLEEVE P-RKS300RSS35

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