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:

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 (Equipped Models) (see Oxygen Sensor Removal (Equipped Models) in the Electrical System chapter ...

Connecting Rod Big End Side Clearance Inspection
Measure connecting rod big end side clearance. Insert a thickness gauge [A] between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance Standard: 0.13 0.38 mm (0.0051 0.0150 in.) Service Limit: 0.58 mm (0.023 in.) If the clearance exceeds ...

For Primary Fuel Injectors
Remove the air cleaner housing (see Air Cleaner Housing Removal). Disconnect the injector connector and connect the harness adapter [A] between these connectors as shown in the figure. Main Harness [B] Primary Fuel Injector #1 [C] Special Tool - Measuring Adapter: 57001-1700 ...