Kawasaki Ninja Service Manual: Exhaust Butterfly Valve Cable Removal

Kawasaki Ninja Service Manual / Engine Top End / Muffler / 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].

Exhaust Butterfly Valve Cable Removal

Loosen the locknuts [A], and turn the adjusters [B] to give the cable plenty of play.

Exhaust Butterfly Valve Cable Removal

Remove the clamp [A].
Remove the upper ends [B] of the exhaust butterfly valve cables from the pulley [C].

Exhaust Butterfly Valve Cable Removal

Remove the muffler body cover (see Muffler Body Removal).
Remove the bolt [A] and pulley cover [B].

Exhaust Butterfly Valve Cable Removal

Remove: Clamp [A] Screw [B] and Stopper [C] (ZX1000J model) Bolt [D] (ZX1000J model) Bolts [E] ZX1000J [F] ZX1000K [G]

Exhaust Butterfly Valve Cable Removal

Loosen the locknuts [A].
Remove the lower ends of the exhaust butterfly valve cables from the pulley [B].
Pull the exhaust butterfly valve cables out of the frame.

Exhaust Butterfly Valve Cable Removal

Exhaust Pipe Installation

Replace the exhaust pipe gaskets [A] and premuffler chamber gasket [B] with new ones. Install the premuffler chamber gasket to the premuffler chamber [C] until it is bottomed so that the cham ...

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 u ...

Other materials:

Battery Removal
Remove the rider’s seat (see Seats section in the GENERAL INFORMATION chapter). Turn the ignition switch to “OFF” and disconnect the (–) cable from the battery. Remove the red cap form the (+) terminal, and disconnect the (+) cables from the battery. NOTE The battery is ...

Safe riding technique
The points given below are applicable for everyday motorcycle use and should be carefully observed for safe and effective vehicle operation. For safety, eye protection and a helmet are strongly recommended. You should be aware of and verify the applicable safety regulations in force prior ...

Rear Master Cylinder Installation
Replace the washers that are on each side of hose fitting with new ones. Install the brake hose [A]. Touch the brake hose to the stopper [B] of the rear master cylinder. Tighten: Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb) Install the master cylinder, the brack ...