NAV - 309 1 Installation instructions: AKRAPOVI EVOLUTION OPEN EXHAUST SYSTEM for the DUCATI 1098, 1098S, 1098R, 848, 1198, 1198S, 1198R, 848EVO Congratulations on purchasing an Akrapovi exhaust system. Please read these installation instructions carefully. If you have any trouble installing the system please contact your authorized dealer! IMPORTANT INFORMATION Exclusion of Certain Liability 1. The manufacturer, importer or dealer shall not be liable for any incidental damage including personal injury or any other damages caused by improper installation or operation of the Akrapovi exhaust system. When installing the Akrapovi exhaust system be careful that the exhaust system does not touch other parts sensitive to high temperature. 2. Akrapovi makes no representation or warranties with regard to damage caused by the improper installation, use and maintenance of the Akrapovi exhaust system. The warranty is limited to defects recognized by our technical department and to normal use, and excludes items subject to normal wear (gaskets and damping wool). The guarantee is void in case of accident, modification, improper or competition use. 3. Do not attempt to install the Akrapovi exhaust system on a motorcycle for which it was not made or tested by Akrapovi. 4. When the exhaust system gets very hot during operation, be careful not to burn yourself on the exhaust system or parts which are in direct contact with it, even when the motor is not running. Also protect other people, especially children, from the injuries mentioned above. 5. In some cases Akrapovi exhaust system kits contain chemical products (ceramic anti-seizing grease; bolt sealant). Handle with care, do not inhale or swallow. Avoid excessive contact with skin, eyes or mucous membranes. Keep out of reach of children. 6. Technical specifications of Akrapovi exhaust systems and related products subject to change without notice. Trademarks The Akrapovi Exhaust System Technology logo is a registered trademark of Akrapovi d.d. Akrapovic website Information about Akrapovi exhaust systems and related products is available on the Akrapovi website at: http://www.akrapovic.com/ Copyright No part of the Akrapovi exhaust system or its documentation may be reproduced or distributed in any form or by any means without the prior written authorization of the Akrapovi company. Akrapovi, d.d. All rights reserved. Symbols The following symbols are used throughout these installation instructions: ! CAUTION OR WARNING INSTALLATION TIP TOOLS REQUIRED TIGHTENING TORQUE USE BOLT SEALANT; Apply 3 to 4 small drops of bolt sealant onto the cleaned and degreased threads before tightening bolts. WARNING! Avoid contact with skin, eyes and mucous membranes. Do not inhale fumes. Keep out of the 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. Avoid excessive skin contact. Keep out of the reach of children. USE ANTI-SEIZING GREASE (white tube); Prevents seizing, corrosion and excessive wear between the titanium components of your exhaust system. WARNING! Avoid eye contact. Avoid excessive skin contact. Keep out of the reach of children. *501941*
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NAV - 309 1
Installation instructions:
AKRAPOVI� EVOLUTION OPEN EXHAUST SYSTEM for the
DUCATI 1098, 1098S, 1098R, 848, 1198, 1198S, 1198R, 848EVO Congratulations on purchasing an Akrapovi� exhaust system. Please read these installation instructions carefully. If you have any trouble installing the system please contact your authorized dealer! IMPORTANT INFORMATION Exclusion of Certain Liability
1. The manufacturer, importer or dealer shall not be liable for any incidental damage including personal injury or any other damages caused by improper installation or operation of the Akrapovi� exhaust system. When installing the Akrapovi� exhaust system be careful that the exhaust system does not touch other parts sensitive to high temperature.
2. Akrapovi� makes no representation or warranties with regard to damage caused by the improper installation, use and
maintenance of the Akrapovi� exhaust system. The warranty is limited to defects recognized by our technical department and to normal use, and excludes items subject to normal wear (gaskets and damping wool). The guarantee is void in case of accident, modification, improper or competition use.
3. Do not attempt to install the Akrapovi� exhaust system on a motorcycle for which it was not made or tested by
Akrapovi�.
4. When the exhaust system gets very hot during operation, be careful not to burn yourself on the exhaust system or parts which are in direct contact with it, even when the motor is not running. Also protect other people, especially children, from the injuries mentioned above.
5. In some cases Akrapovi� exhaust system kits contain chemical products (ceramic anti-seizing grease; bolt sealant).
Handle with care, do not inhale or swallow. Avoid excessive contact with skin, eyes or mucous membranes. Keep out of reach of children.
6. Technical specifications of Akrapovi� exhaust systems and related products subject to change without notice.
Trademarks
The Akrapovi� Exhaust System Technology logo is a registered trademark of Akrapovi� d.d. Akrapovic website
Information about Akrapovi� exhaust systems and related products is available on the Akrapovi� website at: http://www.akrapovic.com/ Copyright
No part of the Akrapovi� exhaust system or its documentation may be reproduced or distributed in any form or by any means without the prior written authorization of the Akrapovi� company.
� Akrapovi�, d.d. All rights reserved.
Symbols The following symbols are used throughout these installation instructions:
! CAUTION OR WARNING INSTALLATION TIP
TOOLS
REQUIRED
TIGHTENING
TORQUE
USE BOLT SEALANT; Apply 3 to 4 small drops of bolt sealant onto the cleaned and degreased threads before tightening bolts. WARNING! Avoid contact with skin, eyes and mucous membranes. Do not inhale fumes. Keep out of the 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. Avoid excessive skin contact. Keep out of the reach of children.
USE ANTI-SEIZING GREASE (white tube); Prevents seizing, corrosion and excessive wear between the titanium components of your exhaust system. WARNING! Avoid eye contact. Avoid excessive skin contact. Keep out of the reach of children.
*501941*
NAV - 309 2
INSTALLATION INSTRUCTIONS
BEFORE INSTALLING CHECK SCHEMATIC OF THE EXHAUST SYSTEM!
! IF ANY ITEMS IN THE AKRAPOVIC 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 AKRAPOVIC EXHAUST SYSTEM.
! THE EXHAUST SYSTEM CAN BE EXTREMELY HOT. ALLOW THE MOTORCYCLE 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 MOTORCYCLE.
REMOVAL OF STOCK EXHAUST SYSTEM:
1. Put the motorcycle on a side stand, we recommend a racing stand. Make sure, that surface is solid and �at. 2. Unscrew the bolts from the muffler clamps and muffler bracket (Figure 1, 2). Unhook the stock springs and remove the
mufflers with welded link-pipes (Figure 3, 4).
T-handle 8 mm wrench T-handle swiveling 10 mm wrench T-handle 3 mm three hexagon key wrench T-handle 4 mm three hexagon key wrench T-handle 6 mm three hexagon key wrench Combination 10 mm wrench Combination 22 mm wrench Screwdriver for headless slotted screws Spring puller
Figure 1 Figure 2
Figure 3 Figure 4
NAV - 309 3
3. Unscrew and remove the right foot-shield and stock heat shield (Figure 5, 6). 4. Remove the lower and the middle parts of the cowling (Figure 7, 8, 9, 10).
Figure 5 Figure 6
Figure 7 Figure 8
Figure 9 Figure 10
NAV - 309 4
5. Cut the marked tie wrap and unscrew the rear cylinder’s lambda sensor - for the models with second lambda sensor only (Figure 11). Unscrew the collector bracket and rear header heat shield (Figure 12, 13). Unhook the springs from rear and front header-collector joints (Figure 14, 15). Temporarily unscrew the servo motor (Figure 16). WARNING: do not disconnect the electrical installation of the servo motor! Partially remove the collector – enough to unscrew the exhaust valve bracket (Figure 17, 18). Remove the cables from the valve (Figure 19). Remove the collector (Figure 20). Completely remove the exhaust valve cables from the motorcycle. Reattach the servo motor on the frame (without the cables!).
Figure 13 Figure 14
Figure 15 Figure 16
Figure 12 Figure 11
NAV - 309 5
6. Unscrew the rear brake oil reservoir for easier access. WARNING: do not disconnect the brake fluid tube! Unscrew and
remove the rear header tube – leave the stock gasket on the exhaust port (Figure 21, 22, 23). Unscrew and remove the front header’s lambda sensor (Figure 24). Unscrew and remove the front header tube – leave the stock gasket on the exhaust port (Figure 25, 26).
Figure 17 Figure 18
Figure 19 Figure 20
Figure 21 Figure 22
NAV - 309 6
INSTALLATION OF THE AKRAPOVI� EVOLUTION EXHAUST SYSTEM: 1. Remove the rubber spacer from stock collector and attach it to Akrapovi� collector (Figure 27, 28).
Figure 23 Figure 24
Figure 25 Figure 26
Figure 27 Figure 28
NAV - 309 7
Figure 29 Figure 30
Figure 31
Figure 36
2. Attach the front header tube (Figure 29). Tighten the lambda sensor (Figure 30). Attach the rear header tube and reinstall the rear brake oil reservoir (Figure 31). Slide the (front and rear headers to collector) link headers on headers and attach the springs (Figure 32, 33, 34, 35). Tighten the rear header bracket to the frame using stock bolt (Figure 36).
9.8Nm 7ftlb
39Nm 29ftlb
9.8Nm 7ftlb
9.8Nm 7ftlb
Figure 32
Figure 33 Figure 34
Figure 35
NAV - 309 8
Figure 39
Figure 37 Figure 38
3. For the models with second lambda sensor only: redirect the lambda sensor’s electrical lead to upper position, tighten the lambda sensor and secure the electrical lead, using tie wrap from installation kit (Figure 37, 38). WARNING: secure the lambda sensor’s electrical lead in such a way, that it doesn’t touch any hot or moving parts!
4. Slide the collector onto the link headers - coat the interior side of the input bushes of the collector with Akrapovi� ceramic
anti-seizing grease (white tube) and attach the springs (Figure 39, 40). 5. Slide the Y link pipe onto the collector - coat the interior side of the input bush of the Y link pipe with Akrapovi� ceramic
anti-seizing grease (white tube) and attach the spring (Figure 41, 42).
39Nm 29ftlb
Figure 40
Figure 41 Figure 42
NAV - 309 9
Figure 45 Figure 46
6. Correctly assemble the Akrapovi� heat shield and tighten it onto the heat shield bracket (Figure 43, 44, 45). Reattach the stock foot shield (Figure 46).
7. Correctly insert the “venturi” inserts into the inlets of both mufflers (Figure 47, 48). Slide the mufflers onto the Y link pipe
(Figure 49). Attach the Akrapovi� springs (Figure 50). Correctly position the carbon-fiber clamps and slide them onto the mufflers. WARNING: open the clamps slightly wider than the diameter of the outer sleeve of the mufflers – do not scrape them along the mufflers outer sleeve! Be careful not to damage paint or any other part of the motorcycle during this process! (Figure 51). Tighten the clamps using stock bolts and spacers (Figure 52). Make sure the mufflers or link pipes are not touching the frame or any other parts of the motorcycle.
9.8Nm 7ftlb
4.9Nm 3.6ftlb
Figure 43 Figure 44
Figure 47 Figure 48
NAV - 309 10
Figure 52
Final installation: 1. Clean grease spots:
a. Muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent).
b. Muffler – titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent).
c. Muffler – carbon-fiber outlet cap: use a soft dry cloth. d. EVOLUTION exhaust: stainless steel header tubes: use a soft cloth sprayed with a contact cleaner, then wipe
with a soft dry cloth e. EVOLUTION exhaust: titanium link headers, collector and Y link pipe: use a soft cloth sprayed with a multi-
purpose spray lubricant (WD-40 or equivalent). Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can damage the sticker.
2. WARNING: after running engine for 30 minutes, tighten the bolts on the Akrapovi� carbon-fiber heat shields!
21Nm 15ftlb
Figure 49 Figure 50
Figure 51
NAV - 309 11
Position of the correctly installed Akrapovi� EVOLUTION exhaust system (Figure 53). 3. Check the operation of the brakes and suspension. 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 your authorized dealer.
! 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 AKRAPOVIC EXHAUST SYSTEMS.
MAINTENANCE OF THE AKRAPOVI� EXHAUST SYSTEM 1. Clean the titanium exhaust components with a multi-purpose spray lubricant (WD-40 or equivalent), carbon fiber exhaust
components with soft and dry cloth and stainless steel components with soft cloth sprayed with contact cleaner, then wipe with soft and dry cloth. Do not use aggressive chemical cleaners, because they can damage the sticker. A change in the color of the exhaust system is normal due to the high temperatures.
2. The wearing out of the muffler silencing material depends on the type of the engine and riding style. Contact your dealer/serviceman if visible changes appear on muffler's outer sleeve or the noise level is increased.
3. Periodically make sure all the bolts and springs are sufficiently tight.
Figure 53
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WARNING:
Please note that certain aftermarket exhaust systems may not comply with applicable California laws and regulations, and may therefore be prohibited for use on California highways or roads, or on roads or vehicles otherwise subject to emissions control requirements.Akrapovič exhaust systems for automobiles and motorcycles mounted downstream of the catalytic converter (also known as “cat-back systems”) are considered “replacement parts” in California by the California Air Resources Board (CARB), and do not require an exemption or executive order from CARB to be sold in California. However, California prohibits the use of any aftermarket exhaust system that modifies, removes or replaces original equipment catalysts, unless CARB has issued an Executive Order as to such part or system.Further, Akrapovič parts or exhaust systems used or intended for use on “racing vehicles” (i.e. a competition vehicle used exclusively for competition on closed-course circuits) do not require an exemption or Executive Order from CARB to be sold in California. However, such parts are prohibited from use on California public highways or roads, even if occasionally used “off-road.”
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