KTM 890 Aventure R Akrapovic DB killer removal

KTM 890 Adventure R DB killer removed from Akrapovic slip on

[JasKro]

Thanks for the tutorial. I just removed mine. Just a few notes to hopefully help any Akro-890 owners planning on doing the same. The weld holding the bolt was too strong for the socket the keep it from rounding off the bolt head. I used my Snap On undersize 8mm (which had to be tapped on since the tolerance is intentionally tight) and it still rounded the bolt head. So I drilled it out. I ended up drilling the hole 9/16” slightly larger that 13mm and would suggest going a couple mm farther down (maybe 27mm since I was drilling at a slight angle. I went up in drill size by 1/64” increments from 1/8” to 3/8” and drilled very slowly since the titanium acts sticky when drilling. Once I reached the depth needed I used a 1/4” reverse drill bit and remaining bolt came right out. To used a toothed flat top burr, 1/2” carbide to remove what was left of the bolt head that was welded in place (so I could used a new bolt if I ever want to put it back in. …but I probably won’t! It sounds the way I wanted it to when I bought the exhaust! To pull out the DB killer I used my small exhaust pipe expander inside the DB killed and a vice-grip/slide hammer and it came right out! I used a 9/16” flush silicone plug to fill the hole and Bob’s your Uncle! Thanks again, cheers!

[ktmadventurer]

Well done must of been more weld on your unfortunate but glad you got it out sounds much better 😊

[redjmototrips]

hello, I made the hole, managed to remove the screw, but impossible to remove the baffle. Was it difficult to remove for you too, how did you manage to get it out? thx

[sritter]

Hi ... I purchased my 790R with an Akropovic without baffle. I am looking for help as am I trying to locate and buy a baffle to install. (mainly before will be doing a 4.5mth doubling ride so just trying to quiet it down for my partner on the back) . Would greatly appreciate if anybody has the part number or source where I can get a replacement baffle..thanks Steve

[sanbje]

How did you manage to remove it? The bolt on mine looks to be welded.