Installation instructions:

*350231*

AKRAPOVIC RACING & EVOLUTION EXHAUST SYSTEM

for the
KAWASAKI KX250F (2006 - 2007 & 2008)
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.

3.

Do not attempt to install the Akrapovic exhaust system on a motorcycle for which it was not made or tested by
Akrapovic.

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 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.

6.

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

TOOLS
REQUIRED

INSTALLATION TIP

TIGHTENING
TORQUE

USE BOLT SEALANT; Apply 1 to 2 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.

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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 6mm three hexagon key wrench
Spring puller

REMOVAL OF STOCK EXHAUST SYSTEM

1.
2.

Put the motorcycle on a side stand, we recommend a racing stand.

For easier access to the muffler remove the rear right panel (Figure 1, 2).

Figure 1

3.

Figure 2

Unscrew the bolt from the metal clamp at the link pipe header tube joint and the bolt from the metal bracket from the link
pipe (Figure 3, 4).

Figure 3

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Figure 4

4.

Unscrew and remove the bolt from the muffler bracket and remove the muffler together with the link pipe (Figure 5, 6).

Figure 5

5.

Figure 6

Unscrew and remove the bolts on the flange of header tube and remove the stock header tube (Figure 7, 8).

Figure 7

Figure 8

INSTALLATION OF THE AKRAPOVIC RACING or EVOLUTION EXHAUST SYSTEM

Installing the header tube:
1. Correctly position and install the Akrapovic carbon-fiber heat shield onto the header tube; make sure the heat / distance
washers are correctly installed (Figure 9, 10, 11, 12).

Figure 9

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Figure 10

9.8Nm
87inlb

Figure 12

Figure 11

2.

Set up the inner sleeve together with the flange and springs; make sure they are correctly oriented; use stock gasket; hand
tighten the flange; (Figure 13, 14).

21Nm
15ftlb

Figure 13

3.

Figure 14

Install the header tube and attach the springs (Figure 15, 16).

Figure 15

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Figure 16

Installing the link pipe with welded muffler:

1. Correctly position the carbon-fiber clamp and slide it onto the muffler - bear in mind the left offset of the carbon-fiber clamp
viewed from the rear. WARNING: open the clamp to slightly wider than the diameter of the outer sleeve of the muffler do
not scrape it along the muffler outer sleeve! (Figure 17).

Figure 17

2.
3.

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 with the link pipe and slide them onto the header tube (Figure 18).

Figure 18

4.

Attach the carbon-fiber clamp to the stock chassis hanging bracket use the bolts, washer and spacers supplied in the
Akrapovic kit. Do not fully tighten. Make sure the additional parts from the Akrapovic kit are correctly installed. (Figure 19,
20, 21).

Figure 19

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Figure 20

21Nm
15ftlb

Figure 21

5.

Attach the spring at the link pipe header tube joint (Figure 22, 23).

Figure 22

6.

Figure 23

For 2006 and 2007 models only: correctly position and install additional link pipe hanging bracket (Figure 24, 25, 26, 27,
28).

Figure 24

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Figure 25

21Nm
15ftlb

Figure 26

Figure 27

21Nm
15ftlb

Figure 28

7.

For 2008 model only: attach the link pipe bracket using stock bolt (Figure 28a).

21Nm
15ftlb

Figure 28a

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8.

Make sure the link pipe and header tubes are not touching the engine or frame.

Final installation:
1. Tighten fully the bolts of the muffler clamp, link pipe bracket and header tube flange to a specified tightening torque (Figure
14, 21, 27, 28, 28a).
2. 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 carbon-fiber outer sleeve: use a soft dry cloth.
c. RACING - stainless steel link pipe, header tube: use a soft cloth sprayed with a contact cleaner, then wipe with a
soft dry cloth.
d. EVOLUTION - titanium link pipe, header tube: use a soft cloth sprayed with a multi-purpose spray lubricant (WD40 or equivalent).
Cleaning will prevent spots from burning onto the surface. Do not use aggressive chemical cleaners, because they can
damage the sticker.
3. Reattach the rear side panel (Figure 29, 30).

9.8Nm
87inlb

Figure 29

4.
5.

Figure 30

WARNING: after running engine for 30 minutes, tighten the bolts on the Akrapovic carbon-fiber heat shield !
Position of the correctly installed Akrapovic RACING or EVOLUTION system (Figure 31, 32).

Figure 31

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Figure 32

6.

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.

2.
3.

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.

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