Kawasaki Z1000SX - Service manual > Exhaust Pipe Removal

• Remove:
  Muffler Bodies (see Muffler Body Removal)
  Oxygen Sensor (see Oxygen Sensor Removal (Equipped Models) in the Electrical System chapter)
• Support the premuffler chamber with the suitable stand [A].
• Loosen the premuffler chamber mounting bolt [B].

• Remove:
  Exhaust Pipe Holder Nuts [A]
  Exhaust Pipe (Premuffler Chamber) [B]
  (In the photo, the radiator has been removed for clarity)

Exhaust Pipe Installation

• Replace the exhaust pipe gaskets [A] with new ones and install them.
• Install the exhaust pipe.
• Tighten the exhaust pipe holder nuts [B] and mounting bolt [C].

  Torque - Premuffler Chamber Mounting Bolt [C]: 34 N*m (3.5 kgf*m, 25 ft*lb)

• Install the muffler bodies (see Muffler Body Installation).
• Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts and nuts.
• Install the removed parts (see appropriate chapters).
  • When installing, run the cables and leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Exhaust Butterfly Valve Cable Removal

• Remove:
  Clamp [A]
  Exhaust Butterfly Valve Cable Upper Ends [B]
  Exhaust Butterfly Valve Cables [C]
• Remove the cable lower ends (see Muffler Body Removal).

Exhaust Butterfly Valve Cable Installation

• Confirm whether pulley [A] is an angle as shown in the figure.

  41.7º +-0.7º [B]

  • This position is original position of the pulley.

NOTE

• Correct the position electrically after confirming use is discontinued and there is no damage when differing from the angle of shown in the figure.

NOTICE Do not correct the pulley position with the tool, forcibly. The actuator damage will occur.

If the angle is wrong, adjust the pulley (see Exhaust Butterfly Valve Actuator Installation in the Fuel System (DFI) chapter).

• Run the exhaust butterfly valve cables correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Install the lower ends of the exhaust butterfly valve cables to the pulley of the right muffler body as shown in the figure.
  • Make sure fit the guides [A] on the cable to the holder grooves [B].

    Open Cable (White) [C]
    Close Cable (Black) [D]

• Tighten the cable locknut securely.
• Install the right muffler body (see Muffler Body Installation).

• Install the upper ends of the exhaust butterfly valve cables to the pulley of the exhaust butterfly valve actuator, following the specified installing sequence.
  • First, install the close cable (black) [A].
  • Second, install the open cable (white) [B].
  • Third, stretch the open cable (white) by using the adjuster [C].
  • Turn the adjuster counterclockwise until the play of the open cable becomes no play.

NOTICE To keep the correct exhaust butterfly valve position, be sure to adjust the open cable first. Do not overstretch the cable.

• Fourth, tighten the adjuster locknut (white) [D] of the open cable securely.
• Fifth, stretch the close cable (black) by using the adjuster [E].
• Turn the adjuster counterclockwise until the play of the close cable becomes no play.
• Sixth, turn the adjuster of the close cable (black) clockwise by 1/2 to 1 rotation.
• Seventh, tighten the adjuster locknut (black) [F] of the close cable securely.

• After installation, cover the dust covers on the adjusters.
• Fix the exhaust butterfly valve cables with the clamps [G].
• Run the exhaust butterfly cables into the holder clamps, and install the holder clamps.
• After connecting the cables, turn the ignition switch ON and make sure that the pulley turns clockwise and counterclockwise, then it returns clockwise slightly.

See also: