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:

Fuel Reserve Switch Inspection
Fill the fuel tank with fuel and close the fuel tank cap. Remove the front seat (see Front Seat Removal in the Frame chapter). Disconnect the fuel pump lead connector [A]. Connect the test light [A] (12 V 3.4 W bulb in a socket with leads) and the 12 V battery [B] to the fuel pu ...

Torque Limiter Removal
Remove: Starter Motor (see Starter Motor Removal in the Electrical System chapter) Throttle Body Assy Holder [A] Breather Hose [B] Roll up the heat insulation rubber plate [C]. Remove: Torque Limiter Cover Bolts [A] Torque Limiter Cover [B] Remove: Torque Limit ...

Intake Air Pressure Sensor #1 Removal
NOTICE Never drop the intake air pressure sensor #1 especially on a hard surface. Such a shock to the sensor can damage it. Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Intake Air Pressure Sensor #1 Connector [A] Remove the intake air ...