Installation Manual for Akrapovič Slip-On Line Exhaust System for Kawasaki Ninja 1000SX / 1100SX

Quick Guide and Safety Information

Before beginning the installation, ensure the motorcycle is securely positioned to prevent tipping. Allow the engine and stock exhaust system to cool completely, as they can become extremely hot. Verify that you have all necessary parts by checking the parts list on the official Akrapovič website. Ensure the exhaust system is compatible with your specific motorcycle model (Kawasaki Ninja 1000SX or 1100SX). Always verify the authenticity of the product using the serial number located on the muffler's inlet pipe.

Tools Required

• T-handle 4 mm hexagon wrench
• T-handle 6 mm hexagon wrench
• T-handle 12 mm wrench
• Torx 30 wrench
• Combination 14 mm wrench
• Flat screwdriver
• Spring puller

Removal of Stock Exhaust

1. Place the motorcycle on a side stand or, preferably, a central racing stand on a solid, flat surface.
2. Loosen the marked clamp, unscrew the muffler's bracket bolt, and carefully remove the stock muffler from the motorcycle.

Installation of Akrapovič Exhaust

1. Install and hand-tighten the clamp with the spring hook. Do not fully tighten it yet.
2. Loosen the bolts on the carbon-fiber clamp, position it correctly on the muffler, and install the gasket and clamp from the Akrapovič kit.
3. Slide the muffler onto the cat box outlet, attach the spring, and hand-tighten the carbon-fiber clamp onto the bracket using the provided bolt, washer, and nut.
4. Align the spring clamp with the spring and tighten both marked clamps to the specified torque (14Nm and 2.1Nm).
5. Align the muffler with the motorcycle and tighten the carbon-fiber clamp bolts to the specified torque (34Nm and 4.9Nm).

Final Installation and Maintenance

Clean any grease spots off the exhaust surfaces after installation to prevent them from burning onto the finish. Do not use aggressive chemical cleaners.

• Titanium outer sleeve: Use a soft cloth sprayed with a multi-purpose spray lubricant (e.g., WD-40).
• Carbon-fiber outer sleeve/outlet cap: Use a soft dry cloth sprayed with all-purpose foam cleaner, then wipe with a soft dry cloth.
• Painted/Chrome parts: Use a soft cloth sprayed with all-purpose foam cleaner, then wipe with a soft dry cloth.
• Stainless steel pipes: Use a soft cloth sprayed with a contact cleaner, then wipe with a soft dry cloth.
• Titanium pipes: Use a soft cloth sprayed with a multi-purpose spray lubricant.

Periodically check that all bolts and springs are sufficiently tight. Note that white smoke from the muffler during the first 100 km and color changes due to high temperatures are normal.

Troubleshooting

If exhaust gas leaks occur at the muffler/pipe clamp connections, ensure the connection is fully joined and tighten the clamp to the specified torque.