2022 Kawasaki KX85 Exhaust System Owners Manual

2022 Kawasaki KX85 Exhaust System

Exhaust System

The exhaust system, in particular the muffler body is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss. If carbon has built up inside the muffler body, exhaust efficiency is reduced, causing engine performance to drop. If the expansion chamber and/or muffler body is badly damaged, dented, cracked or rusted, replace it. Replace the silencer wool if the exhaust noise becomes too loud or engine performance drops.

Silencer Wool Replacement

• Remove the seat bolt and side cover bolt.
• Remove the left side cover.

A. Seat Bolt
B. Side Cover Bolt
C. Left Side Cover

Remove the muffler mounting bolts and washer, and pull the muffler off from silencer joint rubber.

A. Muffler Mounting Bolts
B. Washer
C. Muffler
D. Silencer Joint Rubber

• Remove the liquid gasket on the silencer, tail pipe and baffle.
• Remove the muffler body cover bolts, and pull out the tail pipe.

A. Muffler Body Cover Bolts
B. Tail Pipe
C. Baffle

Remove the O-ring between the silencer wool and tail pipe.

A. O-ring
B. Silencer Wool

• Push out the baffle by tapping the inner pipe with a suitable tool.
• Pull off the silencer wool.

A. Baffle
B. Silencer Wool
C. Push Out

• Replace the silencer wool and O-ring with new ones.
• Install the silencer wool into the silencer.
• Install the O-ring.
• Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area.
• Dry them with a clean cloth.
• Apply liquid gasket to the joint part of the silencer and tail pipe.

A. O-ring
B. Liquid Gasket
C. Silencer
D. Tail Pipe

• Install the baffle and then install the tail pipe into the silencer.
• Apply a non-permanent locking agent to thread of the muffler body cover bolts.
• Tighten the muffler body cover bolts to the specified torque.

Tightening Torque
Muffler Body Cover Bolts: L88 Nm (0.90 kgfm, 78 in 1b)

• Install the muffler.
• Using a high flash-point solvent, clean off any oil or dirt that may be on the liquid gasket coating area. Dry them with a clean cloth.
• Apply liquid gasket to the joint part of the silencer and baffle.

A. Liquid Gasket
B. Silencer
C. Baffle

Install the left side cover.