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:

Wheel Rotation Sensor Air Gap Inspection
Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal in the Wheels/Tires chapter). Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly. Thickness Gauge [A] Wheel Rotation Sensor Air Gap Standard: Front 0.4 1.6 mm ...

Chain Slack Adjustment
Remove the cotter pin, and loosen the axle nut. Loosen the left and right chain adjuster locknuts. A. Axle Nut B. Cotter Pin C. Adjuster D. Locknut If the chain is too loose, turn out the left and right chain adjusters evenly. If the chain is too tight, turn in the left ...

Shifting Gears
Close the throttle while pulling in the clutch lever. Shift into the next higher or lower gear. Open the throttle part way, while releasing the clutch lever. For smooth riding, each gear position should cover the proper rate of speed shown in the table. WARNINGDownshifti ...