Kawasaki Ninja Service Manual: Exhaust Butterfly Valve Cable Installation

Kawasaki Ninja Service Manual / Engine Top End / Muffler / Exhaust Butterfly Valve Cable Installation

Confirm whether pulley [A] is an angle shown in the figure.

41.7° ±7° [B]

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 Cable Installation

NOTICE

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

If the angle is wrong, adjust the pulley (see Exhaust Butterfly Valve Actuator Installation in the Self-Diagnosis System chapter).

Run the exhaust butterfly valve cables correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
Confirm that the exhaust butterfly valve cables do not contact with the swingarm and the brake pedal
Install the lower ends of the exhaust butterfly valve cables to the pulley of the premuffler chamber as shown in the figure.

Open Cable (White) [A] Close Cable (Black) [B]
Tighten the exhaust butterfly valve cable locknuts securely.
Install the pulley cover, and tighten the bolt.

Exhaust Butterfly Valve Cable Installation

Install the upper ends of the exhaust butterfly valve cables to the pulley of the exhaust butterfly valve actuator, following the specified installing sequence.

First, install the close cable (black) [A].

Second, install the open cable (white) [B].

Third, install the clamp [C].

Fourth, stretch the open cable (white) by using the adjuster [D].

Turn the adjuster counterclockwise until the play of the open cable becomes no play.

NOTICE

To keep the correct exhaust butterfly valve position, be sure to adjust the open cable first. Do not overstretch the cable.

Fifth, tighten the adjuster locknut (white) of the open cable securely.

Sixth, stretch the close cable (black) by using the adjuster [E].

Turn the adjuster counterclockwise until the play of the close cable becomes no play.

Seventh, turn the adjuster of the close cable (black) clockwise by 1/2 to 1 rotation.

Lastly, tighten the adjuster locknut (black) of the close cable securely.

After installation, cover the dust covers on the adjusters as shown in the figure.
Fix the exhaust butterfly valve cables with the clamp [F].
After connecting the cables, turn the ignition switch ON and make sure that the pulley turns clockwise and counterclockwise, then it returns clockwise slightly.

Exhaust Butterfly Valve Cable Installation

Exhaust Butterfly Valve Cable Removal

Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Open the clamp [A] and free the cables. Slide the dust covers [B]. Loosen the locknuts [A], and turn t ...

Clutch

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Other materials:

Crankshaft Side Clearance Inspection
Insert a thickness gauge [A] between the thrust washer [B] on the crankcase and the crank web [C] at the #3 main journal to determine clearance. If the clearance exceeds the service limit, replace the thrust washers as a set and check the width of the crankshaft #3 main journal. Cra ...

Starter Motor Disassembly
Remove the starter motor (see Starter Motor Removal). Take off the starter motor through bolts [A] and remove the both end covers [B]. Pull out the armature [A] out of the yoke [B]. NOTE Do not remove the circlip [C] from the shaft. Remove the starter motor terminal lock ...

Spring Preload Adjustment
To adjust the spring preload, turn the spring preload adjuster [A]. The standard adjuster setting is the 6 turns in from the fully counterclockwise position. WARNINGIf both adjusters are not adjusted equally, handling may be impaired and a hazardous condition may result. B ...