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:

Charging Voltage Inspection
Check the battery condition (see Charging Condition Inspection). Warm up the engine to obtain actual alternator operating conditions. Remove the front seat (see Front Seat Removal in the Frame chapter). Check that the ignition switch is turned off, and connect the hand tester [A] to t ...

Subthrottle Valve Actuator Resistance Inspection
Turn the ignition switch to OFF. Disconnect the subthrottle valve actuator connector [A]. Connect a digital meter to the subthrottle valve actuator connector [A]. Measure the subthrottle valve actuator resistance. Subthrottle Valve Actuator Resistance Connections: Y/BK lead [1 ...

Front Brake Pad Installation
Check that the pad spring [A] is in place on the caliper. Push the caliper pistons in by hand as far as they will go. Install the brake pads [A] on the pad spring correctly. Fit the pad into the groove of the caliper as shown in the figure. Install the pad pins while pushing t ...