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:

Brake Disc Warp Inspection
Raise the wheel off the ground with the jack. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 For front disc inspection, turn the handlebar fully to one side. Set up a dial gauge against the disc [A] as shown in the figure and measure disc runout, while turning [B] the ...

Electronic Steering Damper Warning Indicator Light
The yellow light functions as the electronic steering damper warning indicator. The light and warning symbol "ESD" go on if there is a malfunction in the electronic steering damper system. However, this could also be caused by trouble with the charging system (e.g. battery). I ...

Sprocket Wear Inspection
Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter). Worn Tooth (Engine Sprocket) [A] Worn Tooth (Rear ...