Installation instructions: AKRAPOVIC SLIP-ON EXHAUST SYSTEM for the YAMAHA MT 03 (2007-2008)

*501570*

Congratulations on purchasing an Akrapovic 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 Akrapovic exhaust system. When installing the Akrapovic exhaust system be careful that the exhaust system does not touch other parts sensitive to high temperature. 2. Akrapovic makes no representation or warranties with regard to damage caused by the improper installation, use and maintenance of the Akrapovic 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. Do not attempt to install the Akrapovic exhaust system on a motorcycle for which it was not made or tested by Akrapovic. 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. In some cases Akrapovic 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. Technical specifications of Akrapovic exhaust systems and related products subject to change without notice.
Trademarks The Akrapovic Exhaust System Technology logo is a registered trademark of Akrapovic d.d. Akrapovic website Information about Akrapovic exhaust systems and related products is available on the Akrapovic website at:
http://www.akrapovic.net/
Copyright No part of the Akrapovic exhaust system or its documentation may be reproduced or distributed in any form or by any means without the prior written authorization of the Akrapovic company. Akrapovic, 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-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.
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.

NAV - 297

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. T-handle 10mm wrench T-handle 12mm wrench T-handle 10mm swiveling wrench T-handle 5mm three hexagon swiveling key wrench T-handle 5mm three hexagon key wrench Combination 12mm wrench Combination 13mm wrench Spring puller
REMOVAL OF STOCK EXHAUST SYSTEM: 1. 2. Put the motorcycle on a side stand, we recommend a racing stand. Unlock and remove the passenger seat (Figure 1, 2).

Figure 1

Figure 2
Unscrew the bolts and remove the plastic protector between the seat and muffler (Figure 3, 4, 5).

Figure 3

Figure 4

Figure 5

Unscrew the bolts from the anti-vibration license plate / tail light bracket (Figure 6).

Figure 6

Unscrew the bolt from the metal clamp at the muffler - link pipe joint (Figure 7). Unscrew the bolts from the muffler bracket and remove the muffler (WARNING! hold the muffler from underneath) (Figure 8, 9, 10).

Figure 7

Figure 8

Figure 9

Figure 10
INSTALLATION OF THE AKRAPOVIC SLIP-ON STREET LEGAL EXHAUST SYSTEM Installing the Y collector: 1. Coat the bolt and interior of the metal clamp with Akrapovic anti-seize lead-free copper paste (black tube) and correctly install the metal clamp onto the collector (Figure 11). Correctly position and install the collector onto the stock header assembly (Figure 12). Hand tighten the bolt of the metal clamp.

Figure 11

Figure 12
Correctly position and reinstall stock muffler chassis hanging bracket (Figure 13, 14) and install additional Akrapovic metal brackets (Figure 15, 16, 17).

Figure 13

Figure 14

9,8Nm 7ftlb

Figure 15

Figure 16

Figure 17
Attach the press on nut on its position. Position the muffler correctly and slide it onto the outlet side of the Y collector; repeat the process for the other muffler (Figure 18, 19).

Figure 18

Figure 19
Hand tighten the bolt of the welded muffler bracket; repeat the process for the other muffler (Figure 20) Attach the spring at the Akrapovic Y collector Akrapovic link pipe joint; repeat the process for the other muffler WARNING! make sure, that springs pull the link pipe all the way onto the collector use rubber mallet if necessary to tap the connections into place! (Figure 21).

Figure 20

Figure 21
Tighten the bolts of all muffler chassis hanging brackets and welded muffler brackets (Figure 22, 23, 24). Make sure the mufflers are not touching other parts of the motorcycle.

21Nm 15ftlb

Figure 22

Figure 23 6

Figure 24
Tighten the metal clamp at the Akrapovic Y collector stock header assembly joint (Figure 25).

Figure 25

Reattach the plastic protector between the seat and muffler; tighten the rear bolts only (Figure 26, 27). Replace the stock bushing (Figure 28) and correctly position and install additional metal mud guard onto the stock plastic protector (Figure 29, 30).

Figure 26

Figure 27

Figure 28

Figure 29

Figure 30

Unscrew the bolts of the plastic cover near CDI unit (Figure 31). Correctly position and install additional metal mud guard under the plastic cover (Figure 32), tighten both bolts (Figure 33) and reattach the seat (Figure 34).

Figure 31

Figure 32

Figure 33

Figure 34
Final installation: 1. Clean grease spots: a. muffler stainless steel outer sleeve: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth b. stainless steel outer sleeve heat shield: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth c. stainless steel link pipes (muffler): use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth d. stainless steel collector: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth Cleaning will prevent spots from burning onto the surface.
Position of the installed Akrapovic Slip-on Street Legal exhaust (Figure 35).

Figure 35

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 AKRAPOVIC EXHAUST SYSTEM 1. Clean the stainless steel muffler outer sleeve with a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth. Do not use aggressive chemical cleaners. A change in the color of the exhaust system is normal due to the high temperatures. The wearing out of the muffler silencing material depends on the type of the motor and riding style. Contact your authorized dealer if visible changes appear on muffler's outer sleeve or the noise level is increased. Periodically ensure that all the bolts and springs are sufficiently tight.