Kawasaki Ninja Service Manual: Premuffler Chamber Removal

Kawasaki Ninja Service Manual / Engine Top End / Muffler / Premuffler Chamber Removal

Remove: Muffler Body (see Muffler Body Removal) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Front Seat (see Front Seat Removal in the Frame chapter) Oxygen Sensor (Equipped Models) (see Oxygen Sensor Removal (Equipped Models) in the Electrical System chapter)
Remove the lower ends of the exhaust butterfly valve cables from the pulley of the premuffler chamber (see Exhaust Butterfly Valve Cable Removal).
Loosen the exhaust pipe clamp bolt [A].
Remove the bolt [B].
Pull out the premuffler chamber backward from the exhaust pipe.

Premuffler Chamber Removal

Muffler Body Installation

Replace the muffler body gasket [A] with a new one. Install the muffler body gasket to the premuffler chamber [B] until it is bottomed so that the chamfer side faces premuffler chamber. Ins ...

Premuffler Chamber Installation

Replace the premuffler chamber gasket [A] with a new one. Install the premuffler chamber gasket to the premuffler chamber [B] until it is bottomed so that the chamfer side faces exhaust pip ...

Other materials:

Hub Bearing Removal
Remove the wheels (see Front/Rear Wheel Removal), and take out the following. Collars Coupling (Out of rear hub) Grease Seals Use the bearing remover to remove the hub bearings [A]. NOTICE Do not lay the wheel on the ground with the disc facing down. This can damage or warp the d ...

Exhaust Butterfly Valve Actuator Installation
Install the pulley [A] on the actuator so that the hole side [B] align with the groove [C] on the shaft. 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 ad ...

Camshaft Runout Inspection
Remove the camshafts (see Camshaft Removal). Set the camshaft in a camshaft alignment jig or on V blocks. Measure the runout with a dial gauge at the specified place as shown in the figure. If the runout exceeds the service limit, replace the camshaft. Camshaft Runout Standard: TIR ...