Kawasaki J300 - Service manual > Intake Manifold, Muffler

Intake Manifold

Intake Manifold Removal

• Remove:
  Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter)
  Fuel Injector (see Fuel Injector Removal in the Fuel System (DFI) chapter)
• Disconnect the water temperature sensor connector [A].
• Clear the main harness from the clamp [B].

• Remove:
  Intake Manifold Nuts [A]
  Intake Manifold [B]

• If necessary, remove the insulator [A].

Intake Manifold Installation

• Installation is the reverse of removal.
• When the insulator is removed, replace the gasket with a new one.
• Replace the O-ring [A] with a new one.
• Apply grease to the O-ring.

  Torque - Intake Manifold Mounting Nuts: 9.8 N*m (1.0 kgf*m, 87 in*lb)

Muffler

WARNING The muffler can become extremely hot during normal operation and cause severe burns. Do not remove the muffler while it is hot.

Muffler Body Removal

• Remove
  Bolts [A] and Washer
  Muffler End Cover [B]

• Remove:
  Bolts [A] and Washers
  Muffler Side Cover [B]

• Loosen the muffler body clamp bolt [A].
• Remove:
  Muffler Body Mounting Bolts [B]
  Muffler Body [C]

Muffler Body Installation

• Replace the muffler body gasket with a new one.
• Install the muffler body and tighten the muffler body mounting bolts and clamp bolt.

  Torque - Muffler Body Mounting Bolts: 34 N*m (3.5 kgf*m, 25 ft*lb)

• Install the muffler body side cover and tighten the bolts together with the washers.
• Install the muffler end cover [A] and tighten its bolt together with the washers as shown specified sequence [1 - 3].

• Be sure that the gap [A] of the muffler end cover and the muffler side cover is parallel.

  If the gap is not parallel, reinstall the muffler end cover.

• Thoroughly warm up the engine, wait until the engine cools down, and then retighten all bolts.

Exhaust Pipe Removal

• Remove muffler body (see Muffler Body Removal).
• Disconnect the oxygen sensor lead connector (see Oxygen Sensor Removal in the Electrical System chapter).
• Remove:
  Exhaust Pipe Manifold Holder Nuts [A]
  Exhaust Pipe [B]

• If necessary, remove the exhaust pipe cover [A] by removing the bolts [B] and washers.

Exhaust Pipe Installation

• Replace the exhaust pipe gasket with a new one.
• Install the exhaust pipe.
• Tighten:
  Torque - Exhaust Pipe Manifold Holder Nuts: 20 N*m (2.0 kgf*m, 15 ft*lb)
• Install the removed parts (see appropriate chapters).

See also: