2022 Kawasaki KX250 Exhaust System Owners Manual

2022 Kawasaki KX250 Exhaust System

Exhaust System

The exhaust system, in particular the muffler body is designed to reduce exhaust noise and conduct theexhaust gases away from the rider while minimizing power loss. If the muffler body is badly damaged, dented cracked or rusted, replace it.

Muffler Mount Damper Replacement
Remove the seat bolt and side cover bolt.

A. Seat Bolt
B. Side Cover Bolt

• Open the rear part of the side cover slightly out- ward.
• Pull the right side cover backward to clear the hooks and remove the right side cover.

A. Tab
B. Hooks
C. Right Side Cover

• Remove the muffler clamp bolt.
• Remove the muffler bolt (rear).
• Remove the muffler bolt (front) and the muffler body.

A. Muffler Clamp Bolt
B. Muffler Bolt (Rear)
C. Muffler Bolt (Front)
D. Muffler Body

Remove the collars and muffler mount damper.

A. Collars
B. Muffler Mount Damper
C. Muffler Body

• Replace the muffler mount damper with a new one.
• Apply soap and water solution to the muffler mount damper.
• Install the muffler mount damper and collars to the muffler body.
• Install the muffler body, and temporarily tighten the muffler clamp bolt, muffler bolt (rear) and the muf- fler bolt (front).
• Face the muffler clamp bolt upward.
• Firstly, tighten the muffler bolt (front).
• Secondly, tighten the muffler bolt (rear).
• Lastly, tighten the muffler clamp bolt.

A. Muffler Body
B. Muffler Bolt (Front)
C. Muffler Bolt (Rear)
D. Muffler Clamp Bolt

Tightening Torque
Muffler Bolts: 21 Nm (2.1 kgfm, 15 ft:lb) Muffler Clamp Bolt: 11 Nm (1.1 kgfm, 97 in-lb)

Insert the hooks of the right side cover to ribs of the radiator shroud.

A. Side Cover
B. Radiator Shroud
C. Ribs
D. Hooks

Insert the tab of the right side cover into the slot of the rear fender.

A. Tab
B. Right Side Cover
C. Rear Fender

Tighten the side cover bolt and seat bolt to the specified torque.

A. Side Cover Bolt
B. Seat Bolt

Tightening Torque
Side Cover Bolt: 7.0 N-m (0.71 kgfm, 62 in-b) Seat Bolt: 25 N m (2.5 kgfm, 18 ft-lb)

Muffler Replacement
Refer to the Muffler Mount Damper Replacement.