Kawasaki Z400 - Service manual > Muffler

Muffler Body Removal

• Loosen the muffler cover damp bolt [A].
• Remove the muffler cover bolt [B] and collar.
• Remove the muffler cover [C] forward.

Clear the hook [D].

• Loosen the muffler body clamp bolt [A].
• Remove: Muffler Body Mounting Nut and Bolt [B] and Washer Muffler Body  [C]

Exhaust Pipe Removal

• Remove: Right Middle Fairing (see Middle Fairing Removal in -the Frame chapter) Muffler Body (see Muffler body removal)
• Disconnect the oxygen sensor connector [A].
• Open the clamp [B].

• Free the oxygen sensor lead from the brackets [A]
• Open the clamps [B]

• Remove: Exhaust Pipe Holder Nuts [A] Exhaust Pipe

Muffler Body and Exhaust Pipe

• Replace the exhaust pipe gaskets and muffler body gasket with new ones.
• Install the muffler body gasket [A] so that its chamfered side [B] faces front [C].
• Rear [D] Apply grease to the exhaust pipe gaskets.

• Install the following parts and tighten them temporarily.

  Exhaust Pipe Exhaust Pipe Holder Nuts

When tightening the exhaust pipe holder nuts, be sure to follow the specified  sequence [1 - 3].

• Make sure the clearance between the exhaust pipe and oil pan is 10 mm (0.39 in.) [A].

• Fit the muffler body tooth and the muffler body damp hole [A].
• Install the following parts and tighten them temporarily.

  Muffler Body Muffler Body Mounting Bolt [B], Washer and Nut Muffler Body Clamp Bolt [C]

Tighten: Toque - Exhaust Pip. Holder Nub: 12 N-m (1 S kgf*m, 108 In*lb

When tightening the exhaust pipe holder nuts, be sure to follow the above sequence.

• Tighten: Torque - Muffler Body; Mounting Bolt: 25 Nm (2.5 kgf*m, 18 ft-lb) Muffler Body Clamp Bolt: 10 N-m (1.0 kgf*m, 89 in*lb)
• Insert the muffler corer [A] into the muffler body claw (grommet) [B].

Insert the claw [A] into the cover clamp [B] as shown.

45 - 55º [C] Tighten: Torque - muffler Cover  Bolt [D]: 6.9 N*m (0.70 kgf*m, 61 in*lb) Be sure to install the damper and collar [E] Tighten: Tom- Muffler Cover Bolt [F ]: 4,4 N*m (0.M kgf*m, 39 In*lb) *Thoroughly warm up the engine, wait until the engine cods down, retighten all the bob and screw.

Install the removed parts (see appropriate chapters).

See also: