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:

Transmission Assy Removal
Remove: Engine Sprocket (see Engine Sprocket Removal in the Final Drive chapter) Gear Position Switch (see Gear Position Switch Removal in the Electrical System chapter) Collar [A] O-ring [B] Remove: Clutch (see Clutch Removal in the Clutch chapter) Shift Shaft Assembly ...

Exhaust Butterfly Valve Actuator Sensor Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the front seat (see Front Seat Removal in the Frame chapter). Remove the screws [A] and the exhaust butterfly valve actuator temporarily with the cables installed. Disconnect the exhaust butterf ...

Mud Guard Installation
Installation is the reverse of removal. Note the following. Run the hose and lead correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Check the brake line. Apply a non-permanent locking agent to the threads of the mud guard mounting bolts [A, B], and tighten them ...