Kawasaki SXR Wet Pipe Installation Instructions

These instructions provide a step-by-step guide for installing a Wax Racing Products exhaust system on a Kawasaki SXR, focusing on the removal of the stock exhaust and the installation of the new system. Below is a concise breakdown of the process:

1. Disconnect the Battery and Remove Components:

- Disconnect the battery cables.
- Remove the stock exhaust system and the inlet waterline from the exhaust manifold.
- If you are replacing the stock waterbox, do so now; otherwise, leave the 2½” black hose attached to the waterbox inlet.

2. Prepare the Exhaust Manifold:

- Thoroughly clean the gasket surfaces, retaining the stock steel gasket for reuse.
- Cut the stock water-in line to the appropriate length and attach it to the ½” barbed fitting on the new exhaust manifold using a ½” hose clamp.
- Apply sealant to the exhaust manifold gaskets (with arrows pointing upward) and install the manifold onto the cylinders using the stock nuts and washers. Torque to 22-25 ft-lbs.

3. Install Waterline Components:

- Cut the "water overboard" waterline and install the 3/8” plastic T, securing it with the two supplied hose clamps.
- Loosen the clamp on the 2½” black hose on the waterbox inlet and adjust the hose as described.

4. Install the Headpipe and Exhaust Chamber:

- Attach the 4” silicone coupler to the headpipe using a 4” hose clamp. Install the appropriate waterline to the 90-degree fitting on the bottom of the headpipe.
- Install another waterline to the stinger on the exhaust chamber using a hose clamp.
- Position the chamber in the engine compartment, sliding the stinger into the 2½” black hose on the waterbox. Do not tighten the clamps yet.
- Attach the headpipe to the manifold using the supplied gasket, bolts, and lock washers. Secure all bolts.

5. Secure and Finalize Connections:

- Rotate the exhaust chamber to ensure proper clearance and tighten all clamps.
- Attach the appropriate waterline from the headpipe to the fitting on the front cylinder head.

These steps ensure that the new exhaust system is properly installed, enhancing performance while maintaining the reliability of your Kawasaki SXR. Be sure to follow all torque specifications and secure all components as described for optimal results.

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