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:

Commutator Cleaning and Inspection
Clean the metallic debris off the between commutator segments [A]. NOTE Do not use emery or sand paper on the commutator. Check the commutator for damage or abnormal wear. Replace the starter motor with a new one if there is any damage or wear. Visually inspect the commutato ...

Exploded View
10. US, CA, CAL and AU Models 11. ZX1000JD/KD G: Apply grease. L: Apply a non-permanent locking agent. R: Replacement Parts S: Follow the specified tightening sequence. 1. US, CA and CAL Models 2. ZX1000J Model 3. ZX1000K Model 4. AU Model 5. Face the large diameter side re ...

Brake Fluid Level Inspection
Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper lev ...