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Installation instructions

Akrapovič Exhaust Systems:Racing and Evolutionfor theHUSQVARNA TC250/TE250 2009-2010

*502651*

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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 8 mm wrenchT-handle 10 mm wrenchCombination 10mm wrenchSpring puller

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Figure 1

Figure 2

1.2.

Unhookthespringatheadertube-mufflerjointandunscrewthemarkedmufflerbracketbolts.Removethemuffleroffthemotorcycle(Figure 2).

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

3.

Putthemotorcycleonacentralracingstand.Makesure,thatsurfaceissolidandflat.Unscrewthemarkedboltsandremovetheleftsidepanel (Figure 1).

REMOVAL OF STOCK EXHAUST SYSTEM:

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Figure 3

Figure 4

4. Unscrewthetwomarkedboltsandremovethestockheaderpipeoffthemotorcycle(Figure 3).

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

1.

INSTALLATION OF THE AKRAPOVIČ EXHAUST SYSTEM:

Setupthesleevetogetherwiththeflangeandsprings,asshown(Figure 4).

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22Nm16ftlb

22Nm16ftlb

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Figure 5

Figure 6

2. Installtheassembledsleeve,flangeandspringsontothemotorcycleandhandtightenthetwobolts. Installthestockcoolanthosebracket,asshown(Figure 5). WARNING: do not fully tighten the bolts yet! INSTALLATION TIP: use new stock exhaust port gasket.

3. Slidetheheadertubeontothesleeve,attachthespringsandtightentheboltstoaspecifiedtorque(Figure 6).WARNING: before tightening the bolts, make sure, that springs pull the header tube all the way onto the sleeve – use rubber mallet if necessary to tap the connection into place!

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Figure 7

Figure 8

For TC model only:correctlypositionthecarbon-fiberclampandslideitontothemuffler-bearinmindtheright offsetofthecarbonfiber-clampviewedfromtherear(Figure 7). 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!

4.

For TE model only:correctlypositionthecarbon-fiberclampandslideitontothemuffler-bearinmindtheright offsetofthecarbonfiber-clampviewedfromtherear(Figure 8). 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!

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9.8Nm7ftlb

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Figure 9

Figure 10

6. Positionthemufflercorrectlyandslideitontotheoutletsideoftheheaderpipe.Attachthespringandhandtightenthelinkpipebracket,usingstockbolt(Figure 9). WARNING: make sure, that spring pull the muffler all the way onto the header tube – use rubber mallet if necessary to tap the connection into place!INSTALLATION TIP: for Evolution exhaust sistem only: coat the interior side of the input bushe of the muffler with Akrapovič ceramic anti-seizing grease (white tube).

7. For TC model only:alignthemufflerinrespecttothemotorcycleandtightenthemufflercarbon-fiberclampontothesubframe,usingAkrapovičboltandstockwasher(Figure 10).

9.8Nm7ftlb

4.9Nm3.6ftlb

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Figure 11

Figure 12

8. For TE model only:alignthemufflerinrespecttothemotorcycleandtightenthemufflercarbon-fiberclampontothesubframe,usingstockboltandwasher(Figure 11).

Reattachtheleftsidepanelandtightenthemarkedboltstoaspecifiedtorque(Figure 12). 9.

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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-fiberoutletcap:useasoftdrycloth.c. RACING-stainlesssteelmuffler linkpipeandheadertube:useasoftclothsprayedwithacontact

cleaner,thenwipewithasoftdryclothd. EVOLUTION-titaniummufflerlinkpipeandheadertube:useasoftclothsprayedwithamulti-

purposespraylubricant(WD-40orequivalent).Cleaningwillpreventspotsfromburningontothesurface.Donotuseaggressivechemicalcleaners,becausetheycandamagethesticker.

HUSQVARNA TC250/ Complete exhaust system/ RACING LINE, model year: 2009-2010 Product code: S-HU2MR2-QT

(H-HU2MR2) HEADER WITH CHAMBER

(P-VST3PO) STICKER

(P-MCTQ13) CARBON FIBER CLAMP

(P-S2) SPRING

(M-Q03702T) TITANIUM OUTER SLEEVE MUFFLER

(V-TUV045/TI) NOISE REDUCTION INSERT

(V-EC93) END CAP SET

(P-F30) FLANGE

(P-90) INNER SLEEVE

(P-FB26) FITTING MATERIAL

HUSQVARNA TC250/ Complete exhaust system/ EVOLUTION LINE, model year: 2009-2010 Product code: S-HU2MET3-QT

(H-HU2MET2) HEADER WITH CHAMBER

(P-VST3PO) STICKER

(P-MCTQ13) CARBON FIBER CLAMP

(P-S2) SPRING

(M-Q03805T) FULL TITANIUM MUFFLER

(V-TUV045/TI) NOISE REDUCTION INSERT

(V-EC93) END CAP SET

(P-F30) FLANGE

(P-90) INNER SLEEVE

(P-FB26) FITTING MATERIAL

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HUSQVARNA TE250/ Complete exhaust system/ RACING LINE, model year: 2009-2010 Product code: S-HU2MR3-DTA

(H-HU2MR3) HEADER WITH CHAMBER

(P-VST1AL) STICKER

(P-MCTD16) CARBON FIBER CLAMP

(P-S2) SPRING

(M-HU2SO3-DT) MUFFLER

(P-SA003/1) NOISE REDUCTION INSERT

(V-EC129) END CAP SET

(P-F30) FLANGE

(P-90) INNER SLEEVE

HUSQVARNA TE250/ Complete exhaust system/ EVOLUTION LINE, model year: 2009-2010 Product code: S-HU2MET4-DTA

(H-HU2MET3) HEADER WITH CHAMBER

(P-VST1AL) STICKER

(P-MCTD16) CARBON FIBER CLAMP

(P-S2) SPRING

(M-HU2SO4-DT) FULL TITANIUM MUFFLER

(P-SA003/1) NOISE REDUCTION INSERT

(V-EC129) END CAP SET

(P-F30) FLANGE

(P-90) INNER SLEEVE

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