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:

Air Cleaner
A clogged air cleaner restricts the engine’s air intake, increasing fuel consumption, reducing engine power, and causing spark plug fouling. This motorcycle’s air cleaner element consists of a wet paper filter, which cannot be cleaned. The air cleaner element must be replaced in acco ...

Valve Clearance Inspection
NOTE Valve clearance must be checked and adjusted when the engine is cold (at room temperature). Remove: Crankshaft Sensor Cover (see Crankshaft Sensor Removal in the Electrical System chapter) Cylinder Head Cover (see Cylinder Head Cover Removal in the Engine Top End chapter) Turn t ...

Rider’s Seat Installation
Insert the tabs on the front of the rider’s seat into the slots in the frame and secure the seat with mounting bolts. Install the seat cover and bolts. A. Rider’s Seat B. Tabs C. Slots D. Stays ...