Question about kawasaki Ninja 250R Motorcycles

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How to reassemble header for 2002 Kawasaki Ninja 250

I took apart my motorcycle to do some repair work. I took the headers off and can't seem to remember how to put it back on. Any tips?

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First lay out all your exhaust system parts . take inventory.2 ex. gskt.2 mffler gskt,left muffler(short),right muffler(long), header pipe,4 collars, 4 nuts(6 mm),2 holders,2 muffler clamp,2 hanger bolt,2 nut( 10 mm). next. put small dab of grease on exhaust donut gaskets so they will stay in place by themselves when you stick them in place in the exhaust ports ,on the cyl. head.next gather collars, head pipe w/ holders & 6mm nuts, w / 10mm .wrench or socket.tricky part,hold head pipe up in plce to head,take collars w/ lip or bend facing out & put in between pipe holders & ex. donut gaskets,place holders over exhaust studs & install 6 mm nuts & tighten evenly but do not tighten all the way just keeping collars in place. now hang mufflers,w/ gaskets,clamps,nuts, & bolts,loosely.now tghten down head pipe evenly,cheking collars for proper alignment as you tighten.next,tighten mufflers to headpipe w/ clamps using 12 mm socket or wrench.next, tighten mufflers to frame using 14 mm.finally, start bike & check for exhaust leaks.

Posted on Feb 16, 2009

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