Kawasaki Ninja Service Manual: Muffler Body Installation

Kawasaki Ninja Service Manual / Engine Top End / Muffler / Muffler Body Installation

Replace the muffler body gasket [A] with a new one.
Install the muffler body gasket to the premuffler chamber [B] until it is bottomed so that the chamfer side faces premuffler chamber.
Install the muffler body clamp [C] as shown in the figure.

Insert the projection [D] into the slot [E].

Install the muffler body [F].
Tighten the mounting bolt [G] and clamp bolt [H] securely.

Torque - Muffler Body Mounting Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

Muffler Body Installation

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

Install the pad [A] first. Next, install the pad [B].

Muffler Body Cover [C] View F [D] View G [E]

Muffler Body Installation

Muffler Body Removal

Remove: Bolts [A] Muffler Body Cover [B] Loosen the muffler body clamp bolt [A]. Remove the muffler body mounting bolt [B], and pull out the muffler body [C] backward from the pre ...

Premuffler Chamber Removal

Remove: Muffler Body (see Muffler Body Removal) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Front Seat (see Front Seat Removal in the Frame chapter) Oxygen Sensor ...

Other materials:

Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter). Remove the seal cover [A], circlip [B], connector [C] and O-ring [D]. Special Tool - Inside Circlip Pliers: 57001-143 Unscrew the locknut [E] and pivot bolt ...

Starter Motor Installation
NOTICE Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. Clean the starter motor legs [A] and crankcase where the starter motor is ground. Replace the O-ring [A] with a new one. Apply grease to the new O-ring. Tighten: Torque - Starter ...

Cylinder Head Cover Installation
Replace the cylinder head cover gasket [A] with a new one Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth. Apply silicone sealant [B] to the cylinder head as shown in the figure. Sealant - Li ...