Installation instructions: AKRAPOVIC RACING & EVOLUTION EXHAUST SYSTEM for the APRILIA SXV/RXV 4.5/5.5 (2006-2007)

*350461*

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. Akrapovic website Information about Akrapovic exhaust systems and related products is available on the Akrapovic website at:
http://www.akrapovic-exhaust.com/
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. All rights reserved. Symbols The following symbols are used throughout these installation instructions: ! CAUTION OR WARNING INSTALLATION TIP

TOOLS REQUIRED

TIGHTENING TORQUE
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.

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.

NAV - 300

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 8mm wrench T-handle 10mm wrench T-handle 12mm wrench T-handle 13mm wrench T-handle 8mm swiveling wrench T-handle 10mm swiveling wrench Combination 10mm wrench Combination 7mm wrench Spring puller
REMOVAL OF STOCK EXHAUST SYSTEM 1. 2. Put the motorcycle on a side stand, we recommend a racing stand. Remove the seat (Figure 1).

Figure 1

Unscrew and remove outlets of the stock exhaust (Figure 2, 3).

Figure 2

Figure 3
Untighten (do not unscrew!) subframe bolts A on both sides of the motorcycle (Figure 4). Unscrew and remove the bolts B from the stock muffler brackets (Figure 5). Unhook the springs from muffler-header tubes joint and remove the stock muffler (Figure 6, 7).

Figure 4

Figure 5

Figure 6

Figure 7
Unscrew and remove the front header tube (Figure 8, 9). Leave the stock gasket in the exhaust port.

Figure 8

Figure 9
Unscrew and remove the rear header tube (Figure 10, 11). Leave the stock gasket in the exhaust port.

Figure 10

Figure 11
Unscrew and remove the drive chain roller (Figure 12, 13).

Figure 12

Figure 13
Unscrew and remove the breather tubes bracket A (Figure 14).

Figure 14

INSTALLATION OF THE AKRAPOVIC RACING OR EVOLUTION EXHAUST SYSTEM installing the header tubes and collector: 1. Install the Akrapovic breather tubes bracket B and tighten the bolt A (Figure 1, 2, 3).

9.8Nm 7ftlb

Set up the inner sleeves together with the flanges and springs; use stock gasket (Figure 4, 5, 6,7).

12Nm 9ftlb

Figure 7 5
Install the rear header tube first (do not attach the springs yet!) (Figure 8). Position the collector and slide it onto the rear header tube (Figure 9). For evolution exhaust only: coat the interior side of the both inputs of the titanium collector with Akrapovic ceramic anti-seizing grease (white tube), before assembling! Attach the springs on the flange-rear header joint (Figure 10). For SXV/RXV 5.5 model only!: install the distance ring C into the inlet of the collector before installing the front header tube! (Figure 11). Install the front header tube (Figure 12). Attach the springs (Figure 13). For SXV/RXV 5.5 model only!: attach the front header-collector joint spring on the lower spring hole! (Figure 14). For SXV/RXV 4.5 model only!: attach the front header-collector joint spring on the higher spring hole! (Figure 15). Make sure, that all joints are correctly and completely joint.

Attach the springs (Figure 15).

Figure 15

installing the muffler bracket and muffler: 1. Reinstall the the drive chain roller (Figure 16, 17) and tighten the subframe bolts (Figure 18). Uscrew the stock bolts A on the subframe (Figure 19).

22Nm 16ftlb

Figure 16

Figure 17

49Nm 36ftlb

Figure 18

Figure 19
Tighten the Akrapovic muffler bracket to the subframe use the bolts, washer and spacers B supplied in the Akrapovic kit. (Figure 20, 21).

Figure 20

Figure 21
For evolution exhaust only: coat the interior side of the input of the titanium link pipe with Akrapovic ceramic anti-seizing grease (white tube). Correctly position the muffler and slide it onto the collector and attach the springs (Figure 22, 23).

Figure 22

Figure 23
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 (you should see the yellow sticker C). 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 24).

Figure 24

Attach the carbon-fiber clamp to the Akrapovic subframe hanging bracket use the bolt and washer supplied in the Akrapovic kit. Make sure that muffler is aligned and centered with respect to the motorcycle correctly. Make sure the additional parts from the Akrapovic kit are correctly installed. Tighten fully the muffler clamp bolt. (Figure 25, 26).

26Nm 20ftlb

Figure 25

Figure 26

final installation: 1. Check that all bolts and nuts are sufficiently tighten. 2. Make sure the link pipe, muffler or header tube are not touching the engine, frame, electrical wiring 3. Clean grease spots: a. Muffler titanium outer sleeve: use a soft cloth sprayed with a multi-purpose spray lubricant (WD-40 or equivalent). b. RACING - stainless collector, header tubes: use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth. c. EVOLUTION - titanium collector, header tubes: 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. 4. Reattach the seat (Figure 27).

Figure 27

Position of the correctly installed Akrapovic RACING or EVOLUTION system (Figure 28, 29).

Figure 28

Figure 29
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 motor 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.

Aprilia SXV 450/550 (2006-2007) Racing & Evolution Exhaust System
Akrapovic Racing & Evolution Exhaust System
for the Aprilia SXV 450/550 (2006 - 2007)
The Akrapovic Racing and Evolution with their hexagonal muffler are our top systems for this model, and are designed for riders who know how to get the most out of them. Their advantages can be clearly seen from the dyno measurements and clearly felt on the racetrack. The muffler comes equipped with an approved spark arrester. PERFORMANCE Measurements of the Akrapovic EVOLUTION/RACING system on the APRILIA SXV 450/550 (without muffler insert): Power & Torque: These systems allow the motor to breathe fully throughout the rpm range. The most noticeable improvements are the bikes stronger and quicker response from low revs right up to the top end and the overrev range, where the power increase is even more apparent. The torque increase is similar, only more substantial, so the bike gains torque throughout the entire range, especially in the low end and the mid range. CONFIGURATION The Akrapovic Racing and Evolution systems are equipped with the unique Hexagonal offroad design muffler. They differ only in their materials selection: the Racing uses stainless steel, and the Evolution uses titanium. The conical header tube is stainless steel (Racing) or titanium (Evolution). It is attached to the conical SS/titanium link pipe with a sleeve joint secured with a silicon-shielded spring. The link pipe is attached to the muffler in the same manner. The inlet cap is titanium, while the outlet cap for both versions is carbon fiber. The muffler outer sleeve is made of titanium. The system is attached to the bike using Akrapovic carbon-fiber clamps. The system includes an approved spark arrester, which is indicated with a laser engraving on the muffler.

PERFORMANCE

max. rear wheel power HP / rpm
(measured on Dynojet ATV)

Description

Akrapovic Exhaust System Technology copyright 2007, all rights reserved

AKRAPOVIC

max. increased power

Aprilia SXV 450

54.3 / 11000

56.0 / 10800

3.2 / 6500

Aprilia SXV 550

65.9 / 10900

71.0 / 10600

5.4 / 10600

CONFIGURATION

header tubes material tube shape TITANIUM (Evolution) STAINLESS STEEL (Racing) CONICAL
collector link pipe TITANIUM (Evolution) STAINLESS STEEL (Racing) 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 SLEEVE JOINT + SILICON SHIELDED SPRING SLEEVE JOINT + SILICON SHIELDED SPRING TITANIUM CARBON-FIBER NOISE DAMPER SPARK ARRESTER
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
ALU CNC MACHINED SLEEVE JOINT + SILICON SHIELDED SPRING TITANIUM CARBON-FIBER TITANIUM -

Off-Road Program

ADDITIONAL DATA

stock weight comparison (kg) AKRAPOVIC RACING 3.34 noise measurements (dB / rpm) possibility of periodic service without removing A.E.S. legal for street use stock 94.0 / 6600 oil YES NO EVOLUTION 2.84 difference stock - RACING 1.71 AKRAPOVIC 96.0 / 6600 oil filter YES stock EVOLUTION 2.21
Technical specifications of Akrapovic exhaust systems and related products subject to change without notice.
Product code: 106986 (S-A4MR1-ZTA/3) 106987 (S-A4MET1T-ZTA/3)
www.akrapovic-exhaust.com

Exhaust Photo

Product code: 106986 (S-A4MR1-ZTA/3) 106987 (S-A4MET1T-ZTA/3) 3
CARBON-FIBER MUFFLER CLAMP

Bike Photo

Product code: 106986 (S-A4MR1-ZTA/3) 106987 (S-A4MET1T-ZTA/3) 4
Product code: 106986 (S-A4MR1-ZTA/3) 106987 (S-A4MET1T-ZTA/3) 5
Akrapovic Racing Exhaust System

Schematic

(P-SA004) SPARK ARRESTER

(P-HF227) FITTING PARTS

(P-X30) FITTING PARTS

(P-F33) FLANGE

(P-66) INNER SLEEVE
(H-A4MR1) HEADER TUBE SET

(P-ST2A) STICKER

(M-Z00905TA) FULL TITANIUM MUFFLER
(P-MCTZ4) CARBON FIBER CLAMP
APRILIA SXV4.5/5.5 / Racing exhaust system with Titanium muffler, model year:2006-2007 Product code: S-A4MR1-ZTA/3

(P-S2) SPRING

(L-A4MR1) LINK PIPE
(P-KP1) ANTISEIZING GREASE
Product code: 106986 (S-A4MR1-ZTA/3) 6
Akrapovic Evolution Exhaust System
(H-A4MET1) HEADER TUBE SET
APRILIA SXV4.5/5.5 / Evolution exhaust system, model year:2006-2007 Product code: S-A4MET1T-ZTA/3

(L-A4ME1T) LINK PIPE

Product code: 106987 (S-A4MET1T-ZTA/3) 7
for the Aprilia SXV 450 (2006 - 2007)
AKRAPOVIC COMPLETE EXHAUST

STOCK EXHAUST

Diagram / Chart

WhlPwr

EngTrq

8000 EngSpd RPM

for the Aprilia SXV 550 (2006 - 2007)

EngSpd RPM