Kawasaki Ninja Service Manual: Exhaust Pipe Installation

Kawasaki Ninja Service Manual / Engine Top End / Muffler / Exhaust Pipe Installation

Replace the exhaust pipe gaskets [A] and premuffler chamber gasket [B] with new ones.
Install the premuffler chamber gasket to the premuffler chamber [C] until it is bottomed so that the chamfer side faces exhaust pipe [D].
Install the exhaust pipe clamp [E] as shown in the figure.

Insert the projection [F] into the slot [G].

Install the exhaust pipe.
Tighten the following bolts securely.

Exhaust Pipe Holder Nuts [H] Exhaust Pipe Clamp Bolt [I]

Exhaust Pipe Installation

Install the removed parts (see appropriate chapters).
Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts.

Exhaust Pipe Removal

Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Exhaust Pipe Clamp Bolt [A] (Loosen) Remove the exhaust pipe holder nuts [A], and pull out the ...

Exhaust Butterfly Valve Cable Removal

Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Open the clamp [A] and free the cables. Slide the dust covers [B]. Loosen the locknuts [A], and turn t ...

Other materials:

Lower Crankcase Assembly
Install the ball bearing [A] and the oil level inspection window [B] until they are bottomed Apply soap and water solution to the oil level inspection window before installation. Install the new circlip [C]. Apply a non-permanent locking agent to the oil passage plug [D]. Tighten: ...

Water Temperature Sensor Output Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the throttle body assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter). Disconnect the water temperature sensor connector and connect the measuring adapter [A] between these connectors ...

Drive Chain Slack Inspection
Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Drive Chain Slack Adjustment Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wheel Alignment Inspection/Adjustment Refer to the Wheel Alignment Inspection in the Periodic Maintenance ...