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Installation instructions

Akrapovič Exhaust System:Slip-Onfor theSUZUKI DL650 VStorm 2004-2010

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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.

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.

T-handle swivelling 12 mm wrenchT-handle 4 mm three hexagon key wrenchT-handle 5 mm three hexagon key wrenchT-handle 6 mm three hexagon key wrenchCombination 22 mm wrenchSpring puller

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Figure 1

Figure 2

1.2.

Unscrewthelambdasensor(Figure 2).CAUTION: make sure not to damage the sensors’ electrical lead during this process!

3.

Putthemotorcycleonasidestand,werecommendaracingstand.Makesure,thatsurfaceissolidandflat.Unscrewthemarkedboltsandremovetherightpassenger’sfootrestandmuffler’sheatshieldoffthemotorcycle (Figure 1).

REMOVAL OF STOCK EXHAUST SYSTEM:

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Figure 3

Figure 4

4. Untightenthemarkedheaderflanges’boltsandheader-collectorjointclamp(Figure 3).

5. Unscrewthemarkedheader-collectorjointclamp(Figure 4).

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Figure 5

Figure 6

6.

Unscrewthemarkedmuffler’srearbracketboltandremovethemufflerwithcollectoroffthemotorcycle(Figure 6)

WARNING: make sure, not to damage any part of the motorcycle during this process!

7.

Unscrewthemarkedmufflerandcollectorbracketbolts(Figure 5).

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Figure 7

Figure 8

8. Removemarkedmetalcollarfromtheframecollector’sbracket(Figure 7).

9. Removethemarkedrubbercentralstanddamperoffthestockcollector(Figure 8).

WARNING: make sure, not to damage the rubber damper during this process!

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Figure 9

Figure 10

1.

2.

AssemblethestockrubbercentralstanddamperandmetalclampsfromAkrapovičinstallationkit,ontotheAkrapovičfrontpipes,asshown(Figure 9).WARNING: use anti-seize copper paste on metal clamps bolts’ threads!

INSTALLATION OF THE AKRAPOVIČ EXHAUST SYSTEM:

Correctlypositionthecarbon-fiberclampandslideitontothemuffler-bearinmindtheright offsetofthecarbonfiber-clampviewedfromtherear(Figure 10).WARNING: unscrew the clamp’s M5 bolt and open the clamp slightly wider than the diameter of the outer sleeve of the muffler – do not scrape it along the muffler outer sleeve!

39Nm29ftlb

22Nm16ftlb

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Figure 11

Figure 12

4. Slidethelinkpipeontothefrontpipesandattachthesprings.Tightenthelambdasensorandlinkpipe’sbracketontothesubframe,usingstockbolt,washersandnut(Figure 12).WARNING: make sure, that springs pull the link pipe all the way onto the front pipes – use rubber mallet if necessary to tap the connections into place!WARNING: grease only the threads of the lambda sensor with Akrapovič copper paste (black tube)!

3. SlidetheAkrapovičfrontpipesontothefrontandrearstockheaders,asshow(Figure 11). WARNING: hand tighten the metal clamps only!

22Nm16ftlb

22Nm16ftlb

22Nm16ftlb

4.9Nm3.6ftlb

9.8Nm7ftlb

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Figure 13

Figure 14

5.

6. Tightenthefrontheaderflangeandbothmetalclampstoaspecifiedtorques(Figure 14, 15).

Positionthemufflercorrectlyandslideitontotheoutletsideofthelinkpipe.Attachthesprings,alignthemufflerinrespecttothemotorcycleandtightenthecarbon-fiberclampontothesubframe,usingstockbolt,washersandnut.Reinsalltherightpassenger’sfootrest(Figure 13).WARNING: make sure, that springs pull the muffler all the way onto the link pipe – use rubber mallet if necessary to tap the connection into place!

9.8Nm7ftlb

11

Figure 15

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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–titaniumoutersleeve:useasoftclothsprayedwithamulti-purposespraylubricant(WD-40or

equivalent).b. Muffler-carbon-fiberoutersleeve:useasoftdrycloth.c. Muffler–carbon-fiberoutletcap:useasoftdrycloth.d. Headerpipes,linkpipe-stainlesssteel:useasoftclothsprayedwithacontactcleaner,thenwipewith

asoftdrycloth.

Cleaningwillpreventspotsfromburningontothesurface.Donotuseaggressivechemicalcleaners,becausetheycandamagethesticker.

Suzuki DL-650 V-Strom / SLIP ON exhaust system / model year 2004 - 2010Product code: S-S65SO1-RC S-S65SO1-RT

L-S65R1 LINK PIPE

M-R02502C CARBON FIBER OUTER SLEEVE MUFFLERM-R02502T TITANIUM OUTER SLEEVE MUFFLER

H-S65R1R HEADER PIPE REAR

H-S65R1F HEADER PIPE FRONT

P-VST2AL AKRAPOVIC STICKER

V-TUV107 NOISE REDUCTION INSERT

P-S1 SPRING

P-S2 SPRING

P-R8 CLAMP

P-MCCR26 MUFFLER CLAMP FOR CARBON FIBER OUTER SLEEVEP-MCTR26 MUFFLER CLAMP FOR TITANIUM OUTER SLEEVE

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