Kawasaki Ninja Service Manual: Premuffler Chamber Installation

Kawasaki Ninja Service Manual / Engine Top End / Muffler / 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 pipe [C].
Install the exhaust pipe clamp [D] as shown in the figure.
Insert the projection [E] into the slot [F].
Install the premuffler chamber.
Tighten the mounting bolt [G] and clamp bolt [H] securely.

Torque - Premuffler Chamber Mounting Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)

Premuffler Chamber Installation

Install the removed parts (see appropriate chapters).
Thoroughly warm up the engine, wait until the engine cools down, retighten all the bolts.

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 ...

Exhaust Pipe Removal

Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Exhaust Pipe Clamp Bolt [A] (Loosen) Remove the exhaust pipe holder nuts [A], and pull out the ...

Other materials:

Throttle Control System Inspection
Check the throttle grip free play [A]. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play Standard: 2 3 mm (0.08 0.12 in.) Check that the throttle grip [B] moves smoothly from full open to close, and the throttle closes quickly and completely by the ...

Cam Wear Inspection
Remove the camshafts (see Camshaft Removal). Measure the height [A] of each cam with a micrometer. If the cams are worn down past the service limit, replace the camshaft. Cam Height Standard: Exhaust 35.043 35.157 mm (1.3796 1.3841 in.) Intake 38.243 38.357 mm (1.5056 1.5101 in. ...

Side Stand
The motorcycle is equipped with a side stand. A. Side Stand NOTE When using the side stand, turn the handlebar to the left. Do not sit on the motorcycle while it is on its side stand or centre stand. Always kick the stand fully up before sitting on the motorcycle. NOTE The motorcycl ...