Kawasaki Ninja Service Manual: Exhaust Butterfly Valve Actuator Installation

Kawasaki Ninja Service Manual / Self-Diagnosis System / Exhaust Butterfly Valve Actuator (Service Code 63) / Exhaust Butterfly Valve Actuator Installation

Make sure that the groove on the shaft is pointing toward the center of the screw [D].

If the shaft position is incorrect, refer to the following NOTE and procedures to electrically adjust the shaft position.

Exhaust Butterfly Valve Actuator Installation


Torque - Exhaust Butterfly Valve Actuator Pulley Bolt: 4.9 N·m (0.50 kgf·m, 43 in·lb)

Exhaust Butterfly Valve Actuator Installation


NOTICE

If the pulley bolt is tightened without holding, the actuator damage will occur.

This position is original position of the pulley.

NOTE

Correct the position electrically after confirming the use is discontinued and there is no damage when differing from the angle of shown in the figure.

Exhaust Butterfly Valve Actuator Installation


NOTICE

Do not correct the pulley position with the tool, forcibly. The actuator damage will occur.

If the pulley angle is wrong, adjust the angle as follows.

Connect: 2 pins Connector 3 pins Connector

Turn the ignition switch to ON.

Confirm the pulley turns clockwise or counterclockwise then it stops at the original position.

If the pulley position has not been returned to the original position, electrically adjust the shaft position as follows.

Exhaust Butterfly Valve Actuator Installation


Remove: 2 pins Connector 3 pins Connector

Turn the pulley to the original position by turning it clockwise or counterclockwise by connecting the battery to the 2 pin connector terminals. To turn the pulley gradually, intermittently connect the battery positive (+) terminal to the 2 pin connector terminal while connecting the battery negative (–) terminal to the connector.

Pink (–) lead terminal [A] Gray (+) lead terminal [B]

Clockwise: Pink (–) lead terminal to battery (–) terminal Gray (+) lead terminal to battery (+) terminal

Counterclockwise: Pink (–) lead terminal to battery (+) terminal Gray (+) lead terminal to battery (–) terminal

Reconnect the 2 pins connector and 3 pins connector, and turn the ignition switch ON.

Make sure that the pulley turns clockwise and then counterclockwise.

The pulley should returns to the original position.

Turn the ignition switch OFF.

If the pulley does not return to the original position, check the exhaust butterfly valve actuator resistance (see Exhaust Butterfly Valve Actuator Resistance Inspection).

Exhaust Butterfly Valve Actuator Installation


Exhaust Butterfly Valve Actuator Removal
NOTICE Never drop the exhaust butterfly valve actuator especially on a hard surface. Such a shock to the actuator can damage it. Remove: Front Seat (see Front Seat Removal in the Frame chapte ...

Exhaust Butterfly Valve Actuator Inspection
NOTE Be sure the battery is fully charged Remove the front seat (see Front Seat Removal in the Frame chapter). Turn the ignition switch to ON. In the left side view of the motorcycle, check ...

Other materials:

Battery Removal
Turn off the ignition switch. Remove the front seat (see Front Seat Removal in the Frame chapter). Slide the red cap [A]. Disconnect the negative (–) cable [B] and then positive (+) cable [C]. NOTICE Be sure to disconnect the negative (–) cable first. Remove the band [D] ...

Rear Turn Signal Light Bulb Replacement
Remove the upper seat cover (see Seat Cover Removal in the Frame chapter). Disconnect the tail/brake light connector [A]. Turn the socket [A] counterclockwise and remove the socket together with the bulb. Push and turn the turn signal light bulb [A] counterclockwise an ...

Switch Inspection
Using a hand tester, check to see that only the connections shown in the table have continuity. Special Tool - Hand Tester: 57001-1394 For the switch housings and the ignition switch, refer to the tables in the Wiring Diagram. If the switch has an open or short, repair it or replace it w ...