Muffler Body Removal
Warning: To avoid a serious burn, do not remove the muffler when the engine is still hot. Wait until the muffler cool down.
Remove:
- Right Rear Frame Cover (See Rear Frame Cover Removal in the Frame chapter)
- Lower Fairings (See Lower Fairing Removal in the Frame chapter)
- Oxygen Sensor Lead Connector (Europe Models, (See Oxygen Sensor Removal (Europe Models) in the Electrical System chapter)
- Bolts [A]
- Right Front Footpeg Stay [B]
![](https://motoinstruction.ru/img/kawasaki/23/128537.jpg)
- Loosen the exhaust pipe manifold holder nuts [A].
![](https://motoinstruction.ru/img/kawasaki/23/128538.jpg)
- Loosen the muffler body clamp bolt [A].
- Remove the muffler body mounting bolts [B] and nut, and pull the muffler body [C] to backward.
![](https://motoinstruction.ru/img/kawasaki/23/128539.jpg)
Exhaust Pipe Removal
Remove:
- Lower Fairings (See Lower Fairing Removal in the Frame chapter)
- Exhaust Pipe Manifold Holder Nuts [A]
![](https://motoinstruction.ru/img/kawasaki/23/128540.jpg)
- Loosen the muffler body clamp bolt [A].
- Remove the exhaust pipe to forward.
![](https://motoinstruction.ru/img/kawasaki/23/128541.jpg)
Muffler Body and Exhaust Pipe Installation
- Replace the exhaust pipe gaskets [A] and muffler body gasket [B] with new ones and install them.
lnstall the muffler body gasket until it is bottomed so that the chamfer side [C] feces exhaust pipe [D].
Install:
- Muffler Body [E]
- Exhaust Pipe
Tighten:
Torque - Exhaust Pipe Manifold Holder Nuts [F]: 17 Nm (1.7 kgf·m 12 ft·lb)
Muffler Body Mounting Bolts (Front and Rear) [G]: 20 Nm (2.0 kgf·m, 15 ft·lb)
- Install the muffler body clamp bolt [H] as shown.
- Tighten the muffler body clamp bolt.
![](https://motoinstruction.ru/img/kawasaki/23/128542.jpg)
- Install the right front footpeg stay (See Brake Pedal Installation in the Brakes chapter).
- For the Europe Models, route the oxygen sensor lead correctly (See Cable, Wire, and Hose Routing section in the Appendix chapter).
- Thoroughly warm up the engine, wait until the engine cools down, and retighten all the bolts and nuts.