Installation instructions: AKRAPOVIC RACING EXHAUST SYSTEM for the YAMAHA T-MAX 500 (2008)

*350612*

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-exhaust.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 deagreased 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 - 362

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 12mm wrench T-handle 14mm wrench T-handle 15mm wrench T-handle 4mm three hexagon key wrench Combination 14mm wrench Combination 15mm wrench Combination 22mm wrench Spring puller
REMOVAL OF STOCK EXHAUST SYSTEM: 1. 2. Put the motorcycle on a central stand. Make sure, that surface is solid and at. Unscrew and remove the nuts from the flanges of the stock header tubes (Figure 1, 2, 3, 4).

Figure 1

Figure 2

Figure 3

Figure 4
Unscrew the bolt and remove the plastic heat shield (Figure 5, 6). Unscrew and remove the lambda sensor (Figure 7, 8).

Figure 5

Figure 6

Figure 7

Figure 8
Unscrew the bolt from the chassis hanging bracket of the muffler and slightly remove the muffler header assembly (Figure 9, 10).

Figure 9

Figure 10
INSTALLATION OF THE AKRAPOVIC RACING EXHAUST SYSTEM: 1. Insert the header tubes properly (check the spring hooks in figure 12!) and hand tighten the flanges (Figure 11, 12).

Figure 11

Figure 12
Slide the link-pipe onto the headers, attach the springs, tighten the flanges and lambda sensor (Figure 13, 14, 15, 16).

Figure 13

Figure 14

39Nm 29ftlb

21Nm 15ftlb

Figure 15

Figure 16
Correctly position the carbon-fiber clamp and slide it onto the muffler - bear in mind the right offset of the carbon-fiber clamp viewed from the rear. WARNING: open the clamp slightly wider than the diameter of the outer sleeve of the muffler do not scrape it along the muffler outer sleeve! (Figure 17). Position the muffler correctly and slide it onto the outlet side of the link pipe. Insert the aluminium spacer between stock bracket and muffler clamp, hand tighten the muffler clamp to the bracket and attach the springs (Figure 18, 19). Align the muffler in respect to the motorcycle and tighten the bolt on the carbon-fiber clamp (Figure 20). Make sure the headers, link pipe or muffler are not touching the frame or any other part of the motorcycle.

Figure 17

Figure 18

34Nm 25ftlb

Figure 19

Figure 20

Final installation: 1. Clean grease spots: a. Muffler carbon-fiber outer sleeve: use a soft dry cloth. 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. Stainless steel headers and link pipe: 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. Do not use aggressive chemical cleaners, because they can damage the sticker.
Position of the correctly installed Akrapovic RACING system (Figure 21).

Figure 21

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 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. 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. Periodically make sure all the bolts and springs are sufficiently tight.

YAMAHA T-MAX 500

RACING STREET LEGAL EXHAUST SYSTEM
YAMAHA T-MAX 500 RACING STREET LEGAL EXHAUST SYSTEM
The Akrapovic RACING HOMOLOGATED complete system is designed for maxi scooter riders looking for a comfortable ride and a bit of the kind of tuning usually reserved for sport motorcycles. With an Akrapovic exhaust system the Yamaha T-max will gain in both looks and performance. The system has a homologated noise damper plus catalytic converter, and is available without the dampers for the US market. Our system is also 3.95 kg lighter than stock system. PERFORMANCE Measurements of the Akrapovic RACING HOMOLOGATED system on the YAMAHA TMAX (with noise damper): Power & Torque: with the Akrapovic complete system the engine gains significant increases in power and torque. The T-max engine will now have more throttle response throughout the range. We measured max. power increase of 1.3 HP at 7050 rpm. CONFIGURATION The system is composed of cylindrical stainless steel header tubes joined by a conical stainless steel Y link pipe. The joints are sleeve joints held together with silicon-shielded tensioning springs, including the link pipe muffler joint. Inlet cap is made of stainless steel and outlet cap of carbon fiber. The inner perforation is made of stainless steel, while the outer sleeve is made of titanium. For the European market the mufflers have an approved noise damper and catalytic converter, while for the US market the mufflers do not have the noise dampers. PERFORMANCE
stock max. rear wheel power HP / rpm
(measured on Dynojet ATV)

DESCRIPTION

AKRAPOVIC

max. increased power

34.6 / 6950

35.7 / 7000

1.3 / 7050

CONFIGURATION

header tubes material tube shape STAINLESS STEEL CYLINDRICAL
collector link pipe STAINLESS STEEL CONICAL
interference crossover tubes header tube inner sleeves header tubes - collector connection link pipe - muffler connection muffler metal interior muffler clamp muffler insert EU US
S.S. CNC MACHINED (Welded on headers) SLEEVE JOINT + SILICON SHIELDED SPRINGS TITANIUM CARBON-FIBER YES -
lambda sensor header tube flanges collector / header tube link pipe connection muffler inlet cap /outlet cap muffler outer sleeve muffler bracket heat shield catalytic converter
YES S.S. laser cut SLEEVE JOINT + SILICON SHIELDED SPRINGS S.S. - carbon-fiber TITANIUM NO

ADDITIONAL DATA

weight comparison (kg) stock 8.1kg AKRAPOVIC racing 4.15 evolution difference stock - racing 3.95 stock - evolution -
noise measurements (dB / rpm) possibility of periodic service without removing A.E.S.
stock 88 / 3750 oil YES YES
AKRAPOVIC 88 / 3750 oil filter YES
Technical specifications of Akrapovic exhaust systems and related products subject to change without notice.

legal for street use

Product code: S-Y5R1-HCRT
Akrapovi d.d. 2009 all rights reserved

13.12.2010

EXHAUST PHOTO

BIKE PHOTO

YAMAHA T-max 500/ Complete exhaust system/ RACING LINE, STREET LEGAL Product code: S-Y5R1-HCRT

(HS-Y5S1) HEADER SET

SHEMATIC
(P-TT13) TITANIUM SLEEVE BELT (P-S2) SPRING
(P-HF309) FITTING PARTS (P-TT13) TITANIUM SLEEVE BELT

(V-EC31) END CAP SET

(L-Y5R1) LINK PIPE
(V-TUV083) NOISE REDUCTION INSERT
(M-HCR01402T) TITANIUM OUTER SLEEVE MUFFLER (P-MCTR22) CARBON-FIBER CLAMP (P-HST2AL) STICKER
(V-TUV084) NOISE REDUCTION INSERT
MUFFLER REPAIR KITS KIT REPACK SLEEVE Part Nr. P-RPCK30 P-RKS202RT45

DIAGRAM / CHART

STOCK EXHAUST 35
AKRAPOVIC COMPLETE EXHAUST

35,0 EngTrq

WhlPwr