How To Install Slip On Exhaust Ninja 650r: A Step-by-Step Guide

Disclosure: As an Amazon Associate, I earn from qualifying purchases. This post may contain affiliate links, which means I may receive a small commission at no extra cost to you.

So, you’re looking to upgrade your Kawasaki Ninja 650r with a slip-on exhaust? Excellent choice! It’s a fantastic way to enhance both the performance and the aesthetics of your bike. Not only will you likely experience a noticeable increase in horsepower and a more aggressive sound, but you’ll also give your Ninja a fresh, head-turning look.

This guide will walk you through the entire process, step-by-step. We’ll cover everything from gathering the necessary tools and preparing your bike to the final installation and ensuring everything is running smoothly. Don’t worry if you’re not a seasoned mechanic; with a little patience and the right instructions, this is a manageable project for most DIY enthusiasts.

Before we dive in, remember to prioritize safety. Always wear appropriate safety gear, including gloves and eye protection. Also, work in a well-ventilated area. Let’s get started and transform your Ninja 650r!

Table of Contents show

What You’ll Need

Before you even think about touching your bike, gather all the necessary tools and supplies. This will make the process much smoother and prevent any frustrating trips to the hardware store mid-installation.

Essential Tools:

Slip-on exhaust kit: Obviously! Make sure it’s specifically designed for your Ninja 650r model year.
Socket set: A good quality set with various sizes, including metric sockets.
Wrench set: Combination wrenches are ideal.
Torque wrench: Essential for tightening bolts to the correct specifications.
Allen wrench set: Usually included with the exhaust kit, but have a backup set ready.
Penetrating oil (e.g., PB Blaster): For loosening stubborn bolts.
Gloves: Protect your hands.
Safety glasses: Protect your eyes.
Jack or lift (optional, but highly recommended): Makes the job much easier.
Shop towels or rags: For cleaning and wiping.
Anti-seize lubricant: Prevents future corrosion.
Torque specifications: Consult your Ninja 650r’s service manual for torque values.

Preparing Your Ninja 650r

Now that you have your tools ready, let’s prepare your bike for the installation. This involves ensuring your bike is safely positioned and ready for work. (See Also: Won Hundred Willow Slip On Sneakers )

Safety First: Before you do anything, ensure your motorcycle is off, the key is removed, and the bike is in a well-ventilated area.
Cool Down: Allow the exhaust system to cool completely. Working on a hot exhaust system can lead to burns.
Secure the Bike: If you have a motorcycle jack or lift, use it to elevate the bike. This provides better access to the exhaust components. If you don’t have a jack, ensure your bike is on a stable, level surface.
Remove the Fairings (if necessary): Some slip-on exhaust installations may require removing side fairings for better access to the exhaust components. Consult your exhaust kit’s instructions and your Ninja 650r’s service manual to determine if this step is necessary. If so, carefully remove the fairings, storing the fasteners in a safe place.
Protect Your Bike: Place shop towels or rags around the areas you’ll be working on to protect your bike’s paint from scratches.

Step-by-Step Installation Guide

Now, let’s get to the main event: the actual installation of the slip-on exhaust. Follow these steps carefully.

Step 1: Removing the Stock Exhaust

Locate the Exhaust Components: Identify the stock exhaust components you’ll be replacing. This typically includes the muffler (slip-on) and potentially a connecting pipe, depending on your exhaust kit.
Loosen the Clamp(s): Locate the clamp(s) that secure the muffler to the connecting pipe or catalytic converter. Loosen these clamps using a socket or wrench. Sometimes, these clamps can be difficult to loosen due to corrosion. Penetrating oil can be helpful here. Apply the oil and let it sit for a few minutes before attempting to loosen the clamp again.
Remove the Muffler: Carefully remove the stock muffler. It might require some wiggling and twisting to detach it from the connecting pipe. Be mindful of any hangers or brackets that may be supporting the muffler.
Remove the Connecting Pipe (if applicable): Some slip-on kits replace the connecting pipe. If your kit includes a new connecting pipe, remove the stock one. This usually involves removing bolts or springs that connect it to the exhaust headers and catalytic converter.
Inspect and Clean: Inspect the exhaust ports and connecting pipe for any carbon buildup. Clean these areas with a wire brush or shop towel if necessary.

Step 2: Installing the New Slip-on Exhaust

Install the Connecting Pipe (if applicable): If your kit includes a new connecting pipe, install it now. Align the pipe with the exhaust headers and the catalytic converter. Secure it with the provided bolts or springs. Ensure the connections are snug but do not overtighten at this stage.
Install the Muffler: Slide the new slip-on muffler onto the connecting pipe (or catalytic converter, depending on your kit). Ensure the muffler is aligned correctly with any mounting brackets or hangers on the bike.
Secure the Muffler: Tighten the clamp(s) that secure the muffler to the connecting pipe. Make sure the clamp is properly aligned and evenly tightened. Use the torque wrench to tighten the clamp to the manufacturer’s specifications (check your service manual).
Install Mounting Brackets and Hangers: Attach any mounting brackets or hangers that support the muffler. Tighten these bolts to the recommended torque specifications.
Apply Anti-Seize: Before installing any bolts or clamps, apply a small amount of anti-seize lubricant to the threads. This will prevent corrosion and make future removal easier.

Step 3: Final Checks and Adjustments

Double-Check All Connections: Carefully inspect all connections, clamps, and bolts to ensure everything is securely fastened.
Torque All Bolts: Use your torque wrench to tighten all bolts and clamps to the manufacturer’s specified torque values. This is crucial for ensuring a secure and leak-free exhaust system. Refer to your Ninja 650r’s service manual for the correct torque specifications.
Inspect for Leaks: Once everything is tightened, visually inspect the entire exhaust system for any leaks. Look for gaps or areas where exhaust gases might escape.
Reinstall Fairings (if removed): If you removed any fairings, carefully reinstall them, ensuring all fasteners are properly tightened.
Check for Clearance: Make sure the exhaust system doesn’t interfere with any other components on your bike, such as the swingarm, rear tire, or any wiring.

Step 4: Starting and Testing

Start the Engine: Start your Ninja 650r and let it idle. Listen for any exhaust leaks or unusual noises.
Check the Sound: Rev the engine gently and listen to the new exhaust note. Make sure you’re happy with the sound.
Test Ride: Take your bike for a short test ride to ensure everything is functioning correctly and that there are no performance issues. Pay attention to any changes in power delivery.
Re-torque if Necessary: After the first ride, allow the exhaust to cool completely. Then, re-torque all the bolts and clamps. This is important as the components may settle during the initial heat cycles.

Common Issues and Troubleshooting

Even with careful installation, you might encounter a few issues. Here are some common problems and how to address them.

Exhaust Leaks:

If you hear an exhaust leak, check the following:

Clamp Tightness: Ensure the clamps are properly tightened to the recommended torque specifications.
Gasket Condition: Inspect the gaskets (if any) between the exhaust components. Replace any damaged or worn gaskets.
Alignment: Make sure the exhaust components are properly aligned and seated.

Difficulty Removing the Stock Exhaust:

Sometimes, the stock exhaust can be difficult to remove due to corrosion or tight fits. Try these solutions: (See Also: Will Two Brothers Slip On Exhaust Work For Rebel 300 )

Penetrating Oil: Apply penetrating oil to any stuck bolts or clamps and let it soak for several minutes.
Gentle Force: Use a rubber mallet or a block of wood and hammer to gently tap on the exhaust components to help loosen them.
Heat: In extreme cases, you might need to apply heat to the exhaust components with a heat gun or torch (use extreme caution).

Performance Issues:

If you experience performance issues after installing the new exhaust, consider these factors:

Fuel Mapping: Some aftermarket exhausts require adjustments to the fuel mapping to optimize performance. Consult a qualified mechanic or consider installing a fuel management system.
Air Filter: Ensure your air filter is clean and in good condition.
Other Issues: Rule out any other potential mechanical issues, such as spark plugs or fuel delivery problems.

Safety Precautions

Always prioritize safety when working on your motorcycle. Here are some important safety precautions to keep in mind:

Wear Safety Gear: Always wear safety glasses, gloves, and appropriate clothing.
Work in a Well-Ventilated Area: Exhaust fumes can be toxic. Ensure you’re working in a well-ventilated area.
Allow the Exhaust to Cool: Never work on a hot exhaust system. Allow it to cool completely before starting the installation.
Use Proper Tools: Use the correct tools for the job and avoid shortcuts.
Consult the Service Manual: Refer to your Ninja 650r’s service manual for specific instructions and torque specifications.
If in Doubt, Seek Professional Help: If you’re not comfortable with any part of the installation, seek assistance from a qualified mechanic.

Maintenance and Care

Once your new slip-on exhaust is installed, proper maintenance will keep it looking and performing its best.

Regular Cleaning: Clean the exhaust system regularly with a mild soap and water solution. Avoid using harsh chemicals or abrasive cleaners.
Inspection: Inspect the exhaust system periodically for any signs of damage, such as dents, cracks, or leaks.
Tighten Bolts: Check the bolts and clamps periodically to ensure they remain tight.
Lubrication: Apply a small amount of anti-seize lubricant to the threads of any bolts or clamps during maintenance to prevent corrosion.

Verdict

Congratulations! You’ve successfully installed a slip-on exhaust on your Ninja 650r. Enjoy the enhanced performance and sound of your upgraded motorcycle. Remember to ride safely and always follow traffic laws. (See Also: Will You Lose Low End With M4 Slip On Fz07 )

Now that you’ve completed this upgrade, you might consider other performance enhancements, such as a new air filter or a fuel management system. Always research and choose high-quality components for optimal results. Happy riding!

Installing a slip-on exhaust on your Ninja 650r is a rewarding project that can significantly improve your bike’s performance and aesthetics. By following the steps outlined in this guide and taking your time, you can successfully complete the installation yourself. Remember to prioritize safety throughout the process, double-check all connections, and enjoy the enhanced riding experience.

🔥 Read More:

If you’re unsure about any step, don’t hesitate to consult your Ninja 650r’s service manual or seek assistance from a qualified mechanic. With careful attention to detail and a commitment to safety, you’ll be cruising with a louder and more powerful Ninja 650r in no time. Enjoy the ride!