The Arrow Exhaust System for the Kawasaki Z 650 is a high-performance replacement exhaust system designed to enhance engine efficiency and sound. This guide provides a detailed breakdown of the installation process, including specific instructions, tightening torques, and general safety considerations. The information is derived exclusively from the manufacturer's technical documentation and installation manuals provided by Arrow Special Parts S.p.A.
This guide is intended for U.S.-based users and enthusiasts who are undertaking the installation of Arrow exhaust systems for the Kawasaki Z 650. It emphasizes the importance of following the manufacturer's instructions closely to ensure both safety and optimal performance.
Installation Overview
Installing the Arrow Exhaust System for the Kawasaki Z 650 involves a series of steps that require attention to detail and adherence to technical specifications. The process includes the removal of the original exhaust components, installation of the new Arrow exhaust components, and final assembly and tightening of critical hardware.
It is important to note that Arrow Special Parts does not guarantee universal compliance with local laws regarding emissions and noise levels. As such, users are responsible for verifying that the Arrow exhaust system complies with the regulations in their area. Installation should be performed by someone with appropriate technical knowledge or in a professional workshop.
Step-by-Step Installation Instructions
Preparation and Safety Precautions
Before beginning the installation process, it is essential to ensure that the motorcycle is stable and that all necessary tools and components are available. The following precautions and general guidelines should be observed:
- Heat Sensitivity: During and after installation, ensure that the exhaust system does not come into contact with components sensitive to high temperatures. The exhaust can become extremely hot even when the engine is off.
- Warranty Limitations: The warranty is limited to defects recognized by the manufacturer’s technical service and is only applicable for defects resulting from normal use. Components subject to normal wear, such as gaskets and wadding materials, are excluded from the warranty.
- Legal Responsibility: Arrow Special Parts does not warrant that its exhaust systems comply with all legal requirements in every jurisdiction. It is the buyer's responsibility to ensure compliance with applicable laws.
Removal of Original Exhaust Components
To remove the original exhaust system, follow these steps:
- Unplug the Oxygen Sensor: Disconnect the oxygen sensor and remove its harness from the mounts.
- Remove the Shift Lever: Take off the shift lever to allow access to the exhaust components.
- Remove the Nuts Securing Collectors to the Engine: Loosen and remove the nuts that secure the collectors to the engine.
- Remove the Screws and Original Exhaust System: Remove the screw securing the original exhaust system and take it off.
- Remove Spacers and Grommets: Remove the spacers and grommets from the mounts.
These steps ensure that the original exhaust components are removed safely and without damaging the surrounding parts.
Installation of Arrow Exhaust Components
After removing the original exhaust system, the new Arrow components can be installed. This involves fitting new spacers, mounting brackets, and securing the exhaust system in place.
- Install New Spacers: Fit one of the spacers from the fitting kit as specified.
- Secure Mounts: Install the spacers between the two mounts and secure them on the left-hand side using an M8x25mm screw and its washer.
- Mount the Silencer Bracket: Secure the silencer mounting bracket on the right-hand side using an M8x35mm screw and its washer.
- Reconnect the Oxygen Sensor Harness: Fit the oxygen sensor harness on its mount.
- Reinstall the Shift Lever: Fit the shift lever back in place.
Once these components are in place, the collectors and manifold can be installed.
Final Assembly and Tightening
After the Arrow exhaust components are mounted, the final steps involve fitting and tightening the remaining hardware:
- Fit the Collectors: Fit the right-hand (RH) and left-hand (LH) collectors, securing the flanges to the engine. Do not tighten the screws at this stage.
- Install the 2:1 Manifold: Fit the 2:1 manifold and secure the springs.
- Plug the M18/M12 Adaptor and Oxygen Sensor: Connect the M18/M12 adaptor and plug in the oxygen sensor.
- Secure the Oxygen Sensor Harness: Use the plastic strap from the fitting kit to secure the oxygen sensor harness as shown.
- Fit the Silencer and Secure Mounts: Fit the silencer, secure the mount on the inner side of the mounting bracket, and secure the spring.
Once all components are in place, the collectors can be tightened to the cylinders.
Tightening Torques
Correct tightening torques are essential for ensuring the integrity and safety of the installation. The following torques should be used for the relevant screws:
- M5: 5.5 Nm
- M6: 9.5 Nm
- M8: 21 Nm
- M10: 42 Nm
- M12 (Oxygen Sensor): 24 Nm
- M18 (Oxygen Sensor): 28 Nm
It is recommended to use a torque wrench to ensure that each screw is tightened to the correct specification. This helps prevent over-tightening, which could damage the components, or under-tightening, which could lead to leaks or structural failure.
Maintenance and Inspection
Regular maintenance and inspection of the Arrow exhaust system are important for ensuring long-term performance and safety. The following recommendations should be followed:
- Wadding Material Check: The durability of the wadding material can vary depending on the use of the exhaust system. It is recommended to check the internal wadding material every 8,000 to 9,000 km or at least once a year. Inspections should also be performed if there is a noticeable change in the sound of the exhaust or a change in the color of the silencer's external surface.
- Gasket Placement: Check that the original gaskets are properly placed in their seats during installation. This helps prevent leaks and ensures a secure fit.
- General Inspection: After installation, it is recommended to check all screws to ensure they are properly tightened and to check the alignment of the exhaust system.
Legal and Compliance Considerations
As with any aftermarket exhaust system, the Arrow exhaust system may not be compliant with all local laws and regulations. The following considerations should be kept in mind:
- Emissions and Noise Compliance: Arrow Special Parts does not guarantee that its products are universally compliant with laws on emissions and noise. It is the responsibility of the buyer to ensure that the exhaust system meets the requirements in the area where it will be used.
- Product Identification: Arrow exhaust systems may not meet all product identification requirements in certain jurisdictions. Users should verify that the exhaust system can be used legally in their area.
- Warranty Limitations: The warranty is limited to defects recognized by the manufacturer’s technical service and is only applicable for defects resulting from normal use. Normal wear components, such as gaskets and wadding materials, are excluded from the warranty.
Conclusion
The Arrow Exhaust System for the Kawasaki Z 650 is a high-performance solution designed to improve engine efficiency and sound. Proper installation is critical to ensuring the system functions as intended and remains safe to use. The installation process involves the removal of the original exhaust components, installation of the Arrow components, and final assembly and tightening of hardware to the correct specifications.
Users are responsible for verifying that the Arrow exhaust system complies with local laws and regulations. Regular maintenance and inspection are also important for ensuring long-term performance and safety. By following the manufacturer's instructions and using the correct tools and techniques, the Arrow exhaust system can be installed effectively and efficiently.